Coded disc disassembling logistics equipment and disc stacking and disassembling method thereof

Abstract

The invention relates to the field of logistics storage, and discloses a disc disassembling and stacking logistics device and a disc stacking and disassembling method thereof, and the device comprises a rack, a lifting structure arranged on the rack, a forking structure driven by the lifting structure, and a conveying mechanism, a detection system and a control system which are arranged at the bottom of the rack. The detection system comprises a series of detection elements and a forking mechanism detection assembly, and the series of detection elements are arranged on the inlet side of the rack and used for detecting the overall height of the material stack and identifying the identification codes on the trays; the forking mechanism detection assembly is arranged on the forking mechanism and comprises a forking detection element, a safety detection element and a limiting detection element. The control system is electrically connected with the lifting structure, the forking structure, the conveying mechanism and the detection system and used for controlling all the execution mechanisms to act cooperatively based on information of the detection system. According to the invention, complex scenes such as primary and secondary tray mixing and material mixing which cannot be handled by traditional equipment can be stably handled, and the reliability and the automation level of operation are remarkably improved.

Description

Technical Field

[0001] This application relates to the field of logistics and warehousing technology, for example to a pallet unpacking logistics equipment and a method for pallet unpacking and unpacking. Background Technology

[0002] In modern logistics warehousing and manufacturing, the rapid and efficient unpacking (palletizing) and stacking (stacking) of palletized materials is a key link in achieving automated material supply and turnover between warehouses and production lines. The application of automated unpacking and stacking technology has significantly improved logistics efficiency, greatly reduced labor costs, and promoted the development of intelligent warehousing.

[0003] Currently, most automated pallet unpacking and palletizing equipment on the market is designed for stacks of single, standard pallets that are structurally regular and neatly arranged. These devices typically rely on pre-set programs and fixed mechanical structures to perform tasks, resulting in a relatively rigid operating mode. For example, they can efficiently handle pallet stacks consisting entirely of the same type of empty pallets, or stacks of regular materials where all unit goods are of the same size and weight.

[0004] In real-world logistics scenarios, especially in key stages such as production logistics integration, raw material warehousing, and finished product outbound delivery, the complexity of material forms and stacking methods is readily apparent. For example, a case study of automotive parts inbound logistics shows that the material handling and distribution process requires careful design and optimization to cope with a complex supply chain system containing over 3,000 different parts. Furthermore, case studies of material handling system improvements reveal the difficulties and challenges in material handling, and the necessity of improving efficiency and accuracy through process optimization and the use of intelligent logistics systems. Common complex operating conditions mainly encompass the following:

[0005] 1. Mixed use of mother and child pallets: In stacking, some pallets are used as carrying units (child pallets) and move with the goods, while a mother pallet is required at the bottom or in a specific location for stacker cranes or forklifts to pick up and move. This mother pallet is generally a standardized design and is only used for material flow within the yard and is not shipped with the goods. 2. Pallets and materials are mixed together in a stack. That is to say, in a stack, there are units that only place sub-pallets, units that place materials and sub-pallets, and even empty mother pallets. The length, width and stacking thickness of these pallets are different. 3. The pallets are stacked skewed. Due to errors in the previous process or shaking during transportation, some pallets in the stack may shift and no longer maintain a strictly vertical alignment.

[0006] In the application of current logistics automation equipment, the limitations of existing technologies become particularly apparent when faced with complex operating conditions. For example, rigid mechanical structures and basic positioning detection systems struggle to effectively handle the complexity of pallet types, leading to difficulties in accurately locating forklift points and potential collisions during pallet skewing, which can damage pallets or cause equipment malfunctions. Furthermore, the lack of flexible control logic for handling the dynamic insertion and removal of parent and child pallets makes the system difficult to adapt to changing process requirements.

[0007] These problems severely restrict the widespread application of automated equipment in complex logistics scenarios, resulting in many processes still relying on manual intervention, leading to low efficiency and safety hazards. For example, in automated chemical production, equipment depends on microelectronic signal processing and control; once a signal malfunction occurs, it may cause high-energy components to go out of control, posing a safety risk. Furthermore, the implementation of industrial automation projects also brings a series of safety risks due to the complexity of the technology and the diversity of the environment, such as equipment failure, software vulnerabilities, and human error.

[0008] Therefore, there is an urgent need in this field for a palletizing logistics equipment and method with stronger perception, adaptive adjustment and flexible operation capabilities, in order to break through the bottlenecks of existing technologies and meet the stringent requirements of modern smart logistics for flexibility, efficiency and reliability.

[0009] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this application, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0010] To provide a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. This summary is not intended as a general commentary, nor is it intended to identify key / important components or describe the scope of protection of these embodiments, but rather as a prelude to the detailed description that follows.

[0011] This disclosure provides a pallet unpacking logistics equipment and a method for palletizing and unpacking, in order to solve the technical problem that existing pallet unpacking equipment cannot adapt to complex working conditions such as mixing of parent and child pallets, material mixing, and pallet tilting.

[0012] In a first aspect, the present invention provides a pallet unpacking and logistics equipment. The equipment includes a frame, a lifting structure mounted on the frame, a forklift structure driven by the lifting structure, and a conveying mechanism located at the bottom of the frame. The pallet unpacking and logistics equipment further includes a detection system and a control system.

[0013] The detection system includes a series of detection elements and a forklift mechanism detection assembly. The series of detection elements are located on the entrance side of the frame and are used to detect the overall height of the material stack and identify the identification code on the pallet. The fork-taking mechanism detection component is disposed on the fork-taking structure, including a fork-taking detection element for detecting the position of the pallet fork-taking hole, a safety detection element for detecting whether the position of the target pallet is safe, and a limit detection element for detecting the extension depth of the fork. The control system is electrically connected to the lifting structure, forklift structure, conveying mechanism and detection system, and is used to control the coordinated operation of each actuator based on the information from the detection system.

[0014] Secondly, the present invention provides a method for palletizing using the aforementioned palletizing equipment. The method includes: The control conveyor mechanism transports the first material to be stacked directly below the equipment; The subsequent materials to be stacked are paused before they are conveyed to the bottom of the equipment; Based on the material information identified by a series of detection elements, the forklift structure is controlled to pick up and lift the bottom pallet of the material that has been placed in place; Control the subsequent materials to be stacked to be conveyed to the area below the lifting space; The forklift mechanism is controlled to place the forked material onto the subsequent material to be stacked. Repeat the above steps to stack the layers one by one.

[0015] Thirdly, the present invention provides a method for unpacking pallets using the aforementioned pallet unpacking equipment. The method includes: Based on the material stack information obtained from a series of detection elements, the target pallet is determined; Control the lifting structure to drive the forklift mechanism to rise and fall to the target pallet position; Based on the feedback from the detection component of the fork mechanism, the fork structure is controlled to perform the fork operation; Control the forklift structure to lift the target pallet; The control conveyor mechanism transports the bottom layer of material out; Repeat the above steps to dismantle the material stack layer by layer.

[0016] The present disclosure provides a pallet unloading logistics equipment, a pallet loader, and a method for unloading the pallet, which can achieve the following technical effects: The pallet unpacking and palletizing equipment described in the first aspect possesses a powerful adaptive capability due to its integrated sensing system, consisting of a series of detection elements and forklift mechanism detection components, which works in conjunction with the control system. It can proactively identify complex pallet structures, accurately position pallets, and assess the safety of the operating environment in real time, thus achieving a shift from rigid execution to intelligent decision-making. It can reliably handle complex scenarios such as mixed parent and child pallets and material mixing, which traditional equipment cannot handle, significantly improving operational reliability and automation levels.

[0017] The palletizing method described in the second aspect employs a "pause-lift-place" cyclical control logic, combined with real-time detection information to dynamically determine the lifting height, thus achieving a dynamically accumulating, flexible palletizing process. This method allows the palletizing operation to flexibly adapt to mixed inputs of materials of different sizes and types, and intelligently integrates the master pallet, greatly improving the flexibility and efficiency of the palletizing process and ensuring the rationality and stability of stacking.

[0018] The pallet dismantling method described in the third aspect determines the target and dismantles it layer by layer based on the overall pallet structure information, resulting in a clear and safe process. In particular, by controlling the forklift operation through feedback from the forklift mechanism's detection components, the method possesses online sensing and decision-making capabilities, effectively addressing abnormal situations such as pallet tilting and ensuring the safety and smoothness of the dismantling process. Simultaneously, this method can dynamically adjust the discharge mode based on the initial state and downstream demand, achieving a high degree of flexibility in the pallet dismantling output stage.

[0019] The above general description and the description below are exemplary and illustrative only and are not intended to limit this application. Attached Figure Description

[0020] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements. The drawings are not to be scaled. And wherein: Figure 1 This is a schematic diagram of the overall structure of the unpacking and unpacking logistics equipment of the present invention.

[0021] Figure 2 This is a partially enlarged schematic diagram of the forked structure of the present invention.

[0022] Figure 3 This is a schematic diagram of a material stack type that can be handled by the present invention, showing the working condition with a mother pallet at the bottom and packaging materials on the child pallets.

[0023] Figure 4 This is a schematic diagram of another type of material stack that can be handled by the present invention, showing the working condition where there is no mother pallet at the bottom and the child pallet is mixed with packaging materials.

[0024] Figure 5 This is a schematic diagram of another type of material stack that can be handled by the present invention, showing the working condition of an empty pallet stack with a mother pallet at the bottom.

[0025] Figure 6 This is a schematic diagram of a mixed material stack that can be processed by the present invention, showing another combination of sub-pallets and mother pallets.

[0026] Figure label: 1. Frame; 11. Lifting motor; 12. Guide plate; 13. Roller; 14. Roller drive motor; 15. Lifting detection switch; 16. Series detection elements; 2. Material stack; 21. Sub-pallet; 22. Mother pallet; 23. Packaging material; 3. Forklift structure; 31. Safety detection reflector; 32. Limit detection element; 33. Forklift detection reflector; 34. Forklift detection laser switch; 35. Safety detection photoelectric switch; 36. Forklift motor; 37. Rocker arm. Detailed Implementation

[0027] To provide a more detailed understanding of the features and technical content of the embodiments of this disclosure, the implementation of the embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of this disclosure. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be simplified in their depiction to simplify the drawings.

[0028] It should be noted that, unless otherwise specified, the embodiments and features described in the present disclosure can be combined with each other.

[0029] Combination Figure 1-6 This disclosure provides a pallet unpacking logistics equipment. The equipment includes a frame 1, a lifting structure mounted on the frame 1, a forklift structure 3 driven by the lifting structure, and a conveying mechanism located at the bottom of the frame 1. The pallet unpacking logistics equipment also includes a detection system and a control system.

[0030] The detection system includes a series of detection elements 16 and a forklift mechanism detection assembly. The series of detection elements 16 are located on the entrance side of the frame 1 and are used to detect the overall height of the material stack 2 and identify the identification code on the pallet.

[0031] The forklift mechanism detection assembly is disposed on the forklift structure 3, including a forklift detection element for detecting the position of the pallet forklift hole, a safety detection element for detecting whether the position of the target pallet is safe, and a limit detection element 32 for detecting the extension depth of the forklift.

[0032] The control system is electrically connected to the lifting structure, the forklift structure 3, the conveying mechanism, and the detection system, and is used to control the coordinated operation of each actuator based on the information from the detection system.

[0033] The pallet unpacking and unpacking equipment provided in this embodiment enables automated identification, positioning, and unpacking of material stacks 2, improving logistics efficiency and operational safety. By collecting real-time information such as pallet position, posture, and forklift status through a detection system, the control system can precisely schedule the timing and stroke of the lifting structure and forklift structure 3, ensuring a stable and reliable forklifting process. Simultaneously, the conveying mechanism, in conjunction with detection signals, achieves rhythmic and continuous material feeding, effectively reducing the need for manual intervention. This equipment is suitable for various pallet sizes and complex working conditions, possessing good versatility and scalability, meeting the high-efficiency operation requirements of modern intelligent logistics systems.

[0034] Specifically, by integrating a complete sensing system consisting of a series of detection elements 16 and a forklift mechanism detection component, and working in conjunction with the control system, this equipment possesses a powerful adaptive capability for operating conditions. It can proactively identify complex stack structures, accurately position pallets, and assess the safety of the working environment in real time, thereby achieving a shift from rigid execution to intelligent decision-making. It can reliably handle complex scenarios such as the mixing of parent and child pallets 22 and material mixing, which traditional equipment cannot handle, significantly improving the reliability and automation level of operations.

[0035] Optionally, the forklift structure 3 includes two symmetrically arranged fork mechanisms, which are driven by a crank-slider mechanism to increase the forklift stroke.

[0036] Understandably, the crank-slider mechanism converts rotary motion into linear reciprocating motion, driving the fork mechanism to extend and retract horizontally, achieving a large-stroke forking action and ensuring that the pallet can be picked up even when tilted. This structure offers smooth transmission and rapid response, effectively adapting to the operational needs of pallets of varying depths. By precisely controlling the crank angle and slide displacement, combined with advanced sensors and high-precision positioning systems, such as millimeter-level position measurement systems and RTK centimeter-level positioning technology, accurate positioning of the fork extension position can be achieved. This not only improves the accuracy of forking operations but also enhances the safety of the operation process. Simultaneously, this mechanism possesses high mechanical rigidity and load capacity, enabling stable operation under frequent start-stop and heavy-load conditions, ensuring long-term efficient operation of the equipment.

[0037] Optionally, the fork-taking detection element includes an alignment detection component and an anti-collision detection component. The alignment detection component includes a fork-taking detection laser switch 34 disposed at the center of the front end of one fork and a fork-taking detection reflector 33 disposed on another symmetrical fork, used to determine whether the fork and the pallet fork-taking hole are aligned through a laser path. The anti-collision detection component includes a fork-taking detection laser switch 34 disposed at the top of one fork and a fork-taking detection reflector 33 disposed on another symmetrical fork, used to determine whether there is interference between the upper surface of the fork and the pallet insertion hole, and to prevent collision.

[0038] Understandably, if the laser beam emitted by the laser switch can be normally received by the reflector when the forks approach the pallet, it indicates that the fork insertion hole is aligned, and the system determines that the forks can be inserted. If the light path is blocked or cannot form an effective loop, it indicates that there is a misalignment or obstacle, and the control system will adjust the fork position or suspend the operation in time to prevent equipment damage or pallet tipping caused by misoperation. The anti-collision detection component is used to detect the distance between the upper surface of the forks and the top surface of the pallet insertion hole after the fork detection laser switch 34 and the fork detection reflector 33 at the middle of the front end of the forks are aligned, further preventing the risk of collision between the forks and the pallet.

[0039] Furthermore, the forklift detection and positioning system utilizes visual edge processors and deep learning models to detect external RGB and depth images to obtain predicted bounding boxes for the forklifted items, further improving detection accuracy. This non-contact detection method offers fast response and high accuracy, enabling real-time verification of alignment during dynamic operations, significantly improving forklift success rate and operational safety. Moreover, this detection solution is unaffected by environmental factors such as oil and dust on the pallet surface, exhibiting strong environmental adaptability and operational stability, ensuring stable alignment recognition even under complex working conditions. The detection system forms a closed-loop control with the fork drive mechanism, achieving precise feedback and dynamic adjustment during the operation process. By monitoring the forklift alignment status in real time, the control system automatically compensates for mechanical errors and positioning deviations, ensuring accurate insertion of the forks into the pallet fork holes and preventing pallet damage or cargo tipping due to misalignment. This closed-loop mechanism significantly improves the stability and reliability of the equipment in high-paced, continuous operating environments, making it particularly suitable for intelligent manufacturing and unmanned warehousing scenarios with stringent precision requirements, further enhancing the equipment's intelligence level and environmental adaptability.

[0040] Optionally, the safety detection element includes a safety detection reflector 31 and a safety detection photoelectric switch 35 disposed on both sides of the forklift structure 3, used to detect whether the pallet socket has sufficient safe forklift space and to check whether the target pallet is tilted.

[0041] Understandably, when the forklift structure 3 approaches the target pallet, if the signal emitted by the safety detection photoelectric switch 35 can be normally reflected and received by the safety detection reflector 31, it indicates that the pallet is placed upright and without significant tilt. If the signal is abnormal or the received strength deviates from the threshold, the pallet is determined to be tilted, and the system will automatically terminate the forklift action and issue a warning. This detection mechanism can quickly identify abnormal pallet posture in the early stages of forklift operation, effectively avoiding the risk of forklift imbalance or goods slippage caused by uneven loading. Combined with a multi-point reflection layout, it can accurately judge the front-to-back and left-to-right tilt angles of the pallet, improving detection reliability. This safety detection element is linked with the main control system to form a proactive safety protection, further ensuring the safety and stability of the operation process. When the pallet tilt angle exceeds the preset safety range, the system immediately triggers an alarm and locks the hydraulic lifting mechanism to prevent the forks from extending and avoid tipping accidents. At the same time, the system will record abnormal events and upload them to the operation and maintenance platform for subsequent analysis and optimization of the operation process. By monitoring the pallet posture and equipment response status in real time, a closed-loop safety management system that is traceable, predictable, and interventionable throughout the entire process can be achieved, effectively reducing on-site operational risks and improving overall operational efficiency.

[0042] Optionally, the conveying mechanism includes a roller 13 driven by a roller drive motor 14, which is configured to operate briefly when a safety check fails in order to adjust the position of the target pallet by friction.

[0043] Understandably, when the safety detection element detects a slight tilt of the pallet but within the correctable range, the conveying mechanism can activate roller 13 for fine-tuning, automatically correcting the pallet's alignment to the allowable range. This adjustment process is monitored in real-time by the main control system to ensure precise and controllable position correction. Once the pallet's posture returns to normal, the forklift action resumes automatically without manual intervention, improving operational continuity and automation. This design effectively reduces the frequency of operational interruptions caused by slight deviations, further enhancing the system's adaptability and operational efficiency in dynamic warehousing environments. The start / stop and rotation speed of roller 13 are dynamically adjusted by the main control system based on detection feedback, ensuring a smooth, efficient, and undamaged correction process. This adaptive adjustment mechanism is particularly suitable for scenarios with significant fluctuations in incoming material position, enabling high-precision alignment without additional manual intervention. Combined with real-time monitoring by the safety detection element, the system can iteratively adjust multiple times until the posture meets the standards, significantly improving the success rate of operations. The entire correction process is short, typically completed within seconds, without affecting the overall cycle time. For severe misalignment exceeding the automatic correction range, locking and alarms will still be triggered to ensure the safety of equipment and goods. In this case, the system will guide operators to intervene on-site. Subsequent actions can only proceed after the pallet has been repositioned and meets safety requirements. The entire detection and adjustment process is seamlessly integrated into the work cycle, ensuring efficient operation while maintaining high safety.

[0044] The safety detection element also includes limit detection elements 32 disposed on both sides of the fork structure 3, used to detect whether the fork extension depth exceeds the threshold and whether the fork extension and retraction are in place.

[0045] As an example, the unpacking device of this invention mainly consists of three parts: a lifting structure, a forklift structure, and a detection mechanism. The materials conveyed to this device can be of various types (such as...). Figure 3 - Figure 6 (as shown) Form 1: Depalletizing and stacking of all empty pallets; Form 2: Depalletizing and stacking of pallets and materials, with different length, width and stacking thickness of materials on each sub-pallet 21; Form 3: Does the bottom have a mother tray 22? Form 4: Some pallets in the stack of materials are placed at an angle.

[0046] At the entrance of the pallet unpacking logistics equipment, a series of detection elements 16 are installed vertically to detect the height of goods and identify pallet information. Each pallet has an identification code affixed to its side, so that the series of detection elements 16 can record the approximate location information and pallet type of each pallet. Based on the information recorded by the series of detection elements 16, the system will determine the location of the target pallet, activate the lifting motor to drive the forklift structure to lift and lower, and move the forklift to the approximate location of the target pallet.

[0047] The forklift mechanism is equipped with multiple sets of detection elements, including forklift detection elements and safety detection elements. The forklift detection elements detect the forklift holes at both ends of the pallet to ensure precise pallet lifting. The safety detection elements detect whether the target pallet is tilted and whether there is sufficient safety space for the forks to insert, ensuring the forks can horizontally enter the pallet holes. The limit detection element 32 detects whether the forklift extension depth exceeds a threshold, ensuring the effectiveness and safety of the entire lifting process.

[0048] The forklift structure 3 is equipped with two sets of forks, which are completely symmetrical. Each set of forks has two forks, and the two sets of fork mechanisms are configured identically. Taking one set of forks as an example, one fork is equipped with a laser detection switch, and the other fork is equipped with a forklift detection reflector 33.

[0049] The forklift mechanism 3 is a crank-slider motion, which increases the forklift stroke to accommodate pallet goods of different widths and to accommodate misaligned pallet stacks 2 without interference.

[0050] The working principle is as follows: When the laser emitted by the fork detection element can unobstructedly illuminate the detection reflector, it indicates that the position of the fork matches the fork hole position of the target pallet. Otherwise, there is a positional deviation, and the fork needs to be adjusted up and down at the position of the target pallet until the detection is passed.

[0051] Provided the forklift detection element passes the test, if the laser emitted by the safety detection element can unobstructedly illuminate the detection reflector, it indicates that the target pallet at the current height has sufficient fork extension space to ensure that the forks will not collide with the inner wall of the pallet socket when picking up the pallet, thus preventing accidents. If the safety detection fails, the placement of the target pallet needs to be adjusted appropriately. The specific adjustment measures are as follows: turn on the roller 13 motor. Roller 13 will drive the material under the target pallet to move. Since the target pallet is in close contact with the material below, the friction generated between the two will cause the target pallet to move to a certain extent. If the safety monitoring element shows that the detection has passed in a very short time, the roller 13 motor should be stopped immediately; if the safety monitoring element still shows that the detection has failed within a certain period of time, manual adjustment is required until the detection passes.

[0052] Provided that both the forklift detection and safety detection pass, the system will activate the forklift motor 36 to drive the forklift to extend. When the extension depth reaches the set threshold, the limit detection element 32 will respond, thereby stopping the extension action. The following encoder and unloader operations involving forklift movement will be implemented according to the above detection principle.

[0053] This disclosure also provides a method for palletizing using the aforementioned pallet unpacking and palletizing equipment. The method includes: The control conveyor mechanism transports the first material to be stacked directly below the equipment; The subsequent materials to be stacked are paused before they are conveyed to the bottom of the equipment; Based on the material information identified by the series detection elements 16, the forklift structure 3 is controlled to pick up the bottom pallet of the material that has been placed and lift it up; Control the subsequent materials to be stacked to be conveyed to the area below the lifting space; The control forklift structure 3 places the forked material onto the subsequent material to be stacked; Repeat the above steps to stack the layers one by one.

[0054] The palletizing method provided in this disclosure enables automatic identification and accurate stacking of palletized materials of different specifications, effectively improving palletizing efficiency and safety. A dual detection mechanism ensures accurate forklift positioning and sufficient forklift extension space, avoiding the risk of equipment collisions or pallet tipping. Combined with the auxiliary adjustment function of roller 13, the pallet position is dynamically corrected when a detection fails, reducing the frequency of manual intervention. The entire process can achieve stable stacking of multiple layers of materials without manual intervention, making it suitable for high-cycle, intelligent logistics scenarios and significantly enhancing the system's adaptability and operational reliability.

[0055] It achieves a flexible stacking process through a "pause-lift-place" cyclical control logic, combined with real-time detection information to dynamically determine the lifting height. This method enables the palletizing operation to flexibly adapt to the mixed input of materials of different sizes and types, and intelligently integrates the mother pallet 22, greatly improving the flexibility and efficiency of the palletizing process, and ensuring the rationality and stability of stacking.

[0056] Optionally, when the materials to be stacked include the mother pallet 22, in the final stage of stacking, the forklift structure 3 is controlled to lift all the stacked materials as a whole, and the mother pallet 22 is transported below it before the materials are placed on the mother pallet 22.

[0057] Understandably, the mother pallet 22, acting as a load-bearing base, effectively enhances the structural stability of the entire stack of materials, facilitating subsequent forklift transport or automated storage. This control logic identifies the position information of the mother pallet 22 within the material sequence, precisely triggering the overall lifting and bottom placement actions to ensure it is located at the bottom of the stack. The system dynamically adjusts the lifting stroke and conveying sequence based on real-time detection feedback, avoiding placement failures or equipment interference caused by positioning deviations.

[0058] As a preferred option, by introducing AI technology and automated equipment, such as autonomous mobile robots (AMRs) and robotic arms with AI visual recognition technology for picking, the logistics system can achieve fully automated closed-loop palletizing operations without human intervention, significantly improving operational efficiency and safety.

[0059] As an example, the palletizing operation for palletized materials can be performed as follows: First, the conveyor line will transport the materials to be stacked to the bottom of the equipment in sequence. There are several forms of materials to be stacked (single empty sub-pallet 21 / sub-pallet 21 plus packaging material 23 / single empty mother pallet 22). The first stacked material is directly transported to the bottom of the equipment via the conveyor line. The second stacked material will pause briefly before being transported to the bottom of the equipment, waiting for the equipment forks to pick up the bottom pallet of the first stacked material and lift it upwards. Then the second stacked material will continue to be transported to the bottom of the equipment, and the equipment will place the picked-up material on the second material.

[0060] The lifting height of the first stacked material is determined by the height of the second stacked material. Specifically, the "series of detection elements" on the front of the equipment scan and identify the total height of the materials to be stacked, while also identifying the pallet type and size using the identification code on the side of the pallet. The total height identified, plus a certain margin of error, is the lifting height of the first stacked material.

[0061] Similarly, the third stacked material will pause briefly before being conveyed under the equipment, waiting for the equipment forks to pick up the bottom pallet of the second stacked material and lift it upwards. Then, the third stacked material will continue to be conveyed directly under the equipment. This process is repeated until the height of the stacked material is continuously increased until the specified height range H±k is reached, where k is the deviation value of the range. For example, the pallet stacking height should be less than 4 times the length of the short side of the pallet, and the height of manually stacked goods should not exceed 2 meters.

[0062] It should be noted that if the first material to be stacked is a single empty sub-pallet 21 or a sub-pallet 21 plus packaging material 23, then the general material stacking process shall be followed. If the first material to be stacked is a single empty mother pallet 22, the pallet is first transported to the other side under the equipment and placed temporarily for a period of time. Then the general material stacking process begins. When the difference between the total stacking height and the limit value is greater than the height of one mother pallet 22, the forks will no longer accept new materials to be stacked. At this time, the forks will pick up all the stacked materials and lift them to a certain height. The mother pallet 22 will then flow back to the bottom of the equipment, and the forks will place the materials on the mother pallet 22.

[0063] If a single empty mother pallet 22 is delivered during the stacking process, the forklift will first pick up the stacked material from the bottom and lift it to a certain height. Then, it will transport the mother pallet 22 to the other side under the equipment and place it temporarily for a period of time. The forklift will then put the material down and repeat the normal material stacking process until the difference between the total stacking height and the limit value is just greater than the height of one mother pallet 22. At this point, the forklift will no longer accept new material to be stacked. After the forklift picks up all the stacked material and lifts it to a certain height, the mother pallet 22 flows back to the bottom of the equipment, and the forklift will then place the material on the mother pallet 22.

[0064] It is important to note that only one empty mother pallet 22 will appear in each complete stacking process, but the conveying order of the mother pallet 22 is not fixed.

[0065] This disclosure provides a method for unpacking pallets using the aforementioned pallet unpacking equipment. The method includes: Based on the information of the material stack 2 obtained by the series of detection elements 16, the target pallet is determined; The lifting structure drives the forklift mechanism 3 to rise and fall to the target pallet position; Based on the feedback from the detection component of the forklift mechanism, the forklift structure 3 is controlled to perform the forklift operation; Control the lifting structure 3 to lift the target pallet; The control conveyor mechanism transports the bottom layer of material out; Repeat the above steps to dismantle the material stack 2 layer by layer.

[0066] The pallet dismantling method provided in this embodiment can efficiently and accurately complete the dismantling of material stack 2, significantly improving the level of logistics automation and reducing the risk of manual intervention. This method, through multi-sensor fusion and closed-loop control strategies, achieves real-time monitoring and dynamic adjustment of the pallet position and attitude, ensuring the stability and accuracy of forklift actions, while effectively avoiding the risk of equipment collisions or material tipping due to positioning deviations.

[0067] The dismantling method disclosed herein determines the target layer by layer and dismantles it based on the overall stack structure information, with a clear and safe process. In particular, by controlling the forklift operation through feedback from the detection components of the forklift mechanism, the method possesses online sensing and decision-making capabilities, effectively handling abnormal situations such as pallet tilting and ensuring the safety and smoothness of the dismantling process. Simultaneously, the method can dynamically adjust the discharge mode according to the initial state and downstream demand, achieving a high degree of flexibility in the dismantling output stage.

[0068] As a preferred option, combining visual guidance and torque feedback mechanisms allows the system to adapt to different pallet sizes and irregular stacking scenarios, further enhancing operational flexibility and environmental adaptability. The entire pallet unpacking process is monitored by safety protection devices; any abnormal conditions detected immediately trigger an emergency stop and alarm, ensuring equipment and personnel safety. The system intelligently plans material distribution paths based on the unpacking progress, allocating outbound materials to corresponding conveyor lines or temporary storage areas according to preset logic, enabling parallel processing of multiple tasks and dynamic path optimization, thus improving overall operational efficiency. After the unpacking operation is completed, the system automatically records material information for each layer and uploads it to the management center, achieving full data traceability. Simultaneously, the equipment self-check module is activated to diagnose the status of forks, lifting mechanisms, and sensors, ensuring subsequent operational reliability. Through a remote monitoring platform, maintenance personnel can view equipment operating parameters and historical operation records in real time, promptly identifying potential faults. This solution is not only suitable for standardized factory environments but can also flexibly adjust the process flow according to on-site needs, meeting the efficient logistics requirements of multi-variety, small-batch production models.

[0069] Optionally, the steps of the control forklift structure 3 to perform the forklift operation include: when the safety detection fails, generating a position adjustment command and controlling the conveying mechanism to run briefly to correct the position of the target pallet through friction.

[0070] Understandably, by monitoring pallet edge deviation in real time and combining it with slight starts and stops of the conveyor belt, dynamic correction of the pallet position can be achieved, completing posture adjustment without adding extra mechanical devices. After posture adjustment, the system re-performs a safety check, and continues subsequent operations only after confirming that the forklift conditions are met, effectively improving the success rate of operations under complex conditions. This mechanism is particularly suitable for scenarios where pallets are worn, deformed, or have poor initial stacking accuracy, enhancing the robustness and adaptability of the pallet unpacking system.

[0071] Optionally, during the unpacking process, depending on whether there is a mother pallet 22 at the bottom of the initial material stack 2 and the order requirements, it is dynamically decided whether to supplement the unpacked material with a mother pallet 22.

[0072] Understandably, when the system detects that the initial stack lacks a mother pallet 22 and the downstream process requires the material to be attached to the mother pallet 22, it will automatically schedule the empty mother pallet 22 feeding unit. Through an auxiliary positioning mechanism, the material will be precisely combined with the new mother pallet 22 before being output. If the downstream process does not require a mother pallet 22 or the original stack already has a reusable mother pallet 22, the material will be directly released into the conveying process, avoiding redundant operations. This decision-making mechanism is based on a collaborative judgment using preset process rules and real-time sensor data, balancing operational efficiency and resource utilization, effectively supporting flexible production needs. The system can dynamically adjust the diversion strategy according to material characteristics and flow information, ensuring that high-priority order materials enter the next stage first.

[0073] As an example, the unpalletizing process can be performed as follows: The unpacking principle is to separate each sub-pallet 21 and its material from the material stack 2 from the bottom to the top, and equip it with a mother pallet 22 for bottoming and circulation (if necessary).

[0074] When palletized materials (empty sub-pallets 21 stacks / material stacks 2 containing sub-pallets 21 and packaging material 23) enter the unpacking and palletizing machine, a series of longitudinally arranged detection elements 16 will obtain information about the palletized materials (including the approximate position, type, size, and total height of each pallet) based on the identification codes on the pallets. The system will then designate the second sub-pallet 21 from the bottom of the stack as the target pallet based on the information obtained from the detection elements 16, and the target pallet will change in real time as the unpacking process progresses.

[0075] In the initial state, the fork structure is in the retracted state and can be at any height of the frame 1. After the series detection switch 16 detects that the goods have reached the designated position, it starts the lifting motor 11 to drive the fork structure to rise and fall to the target pallet.

[0076] (1) If the material has a mother tray 22 at the bottom in the initial state, such as Figure 3 , Figure 5 and Figure 6 As shown. When the forklift structure 3 moves to the target pallet position, and all detection elements on it pass the test, the forks are inserted into the pallet's insertion holes. After successful insertion, the entire forklift structure 3 is raised a safe distance to make room for the transport of materials below. Subsequently, the bottom conveyor starts, transporting the bottommost mother pallet 22 and its receiving daughter pallet 21, or the mother pallet 22 and its receiving daughter pallet 21, along with the materials on them, away together. At this point, the first set of materials is unpacked.

[0077] (2) When dismantling the second set of materials, all materials need to be picked up by forks and raised to a certain height (at least the height of a single empty mother pallet 22). At this time, the single empty mother pallet 22 will be transported to the bottom of the equipment on the conveyor line. Then the forks will place all materials on the mother pallet 22 and repeat the steps in (1). The dismantling of the entire stack of materials is gradually realized.

[0078] (3) If the initial inspection in the initial state finds that the bottom of the goods does not have the mother pallet 22, such as Figure 4 As shown, repeat steps (2) to gradually dismantle the entire stack of materials.

[0079] If the material flow does not require the mother pallet 22 due to order demand, then there is no need to add a mother pallet 22 as a base when dismantling the pallet; the material can be directly dismantled and output for flow.

[0080] The foregoing description and accompanying drawings fully illustrate embodiments of the present disclosure to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operation may vary. Parts and features of some embodiments may be included or substituted for parts and features of other embodiments. Embodiments of the present disclosure are not limited to the structures described above and shown in the accompanying drawings, and various modifications and changes may be made without departing from its scope. The scope of the present disclosure is limited only by the appended claims.

Claims

1. A palletizing and depalletizing equipment, comprising a frame (1), a lifting structure arranged on the frame (1), a fork structure (3) driven by the lifting structure, and a conveying mechanism arranged at the bottom of the frame (1); characterized in that, Also comprising a detection system and a control system; The detection system comprises a series of detection elements (16) and a fork mechanism detection assembly, The series of detection elements (16) are arranged at the entrance side of the rack (1) and used for detecting the overall height of the material pile (2) and identifying the identification code on the pallet; The fork mechanism detection assembly is arranged on the fork structure (3) and comprises a fork detection element for detecting the fork hole position, a safety detection element for detecting whether the target pallet pose is safe, and a limit detection element (32) for detecting the extension depth of the fork; The control system is electrically connected with the lifting structure, the fork structure (3), the conveying mechanism and the detection system, and is used for controlling the cooperative action of each executing mechanism based on the information of the detection system.

2. The de-palletizing carousel logistics equipment of claim 1, wherein, The fork structure (3) comprises two groups of fork mechanisms arranged symmetrically, and the fork mechanisms are driven by a crank slider mechanism to increase the fork stroke.

3. The de-palletizing carousel logistics equipment of claim 2, wherein, The fork detection element comprises an alignment detection assembly and a collision avoidance detection assembly, the alignment detection assembly comprises a fork detection laser switch (34) arranged at the middle of the front end of one fork and a fork detection reflection plate (33) arranged on the other symmetrical fork, which is used for judging whether the fork and the pallet fork hole position are aligned through the laser passage, and the collision avoidance detection assembly comprises a fork detection laser switch (34) arranged on the upper part of one fork and a fork detection reflection plate (33) arranged on the upper part of the other symmetrical fork, which is used for judging whether the upper surface of the fork and the pallet jack are interfered to prevent collision.

4. The de-palletizing carousel logistics equipment of claim 1, wherein, The safety detection element comprises safety detection reflection plates (31) arranged on both sides of the fork structure (3), safety detection photoelectric switches (35) and limit detection elements (32), which are used for detecting whether the target pallet is skewed and whether the fork is in place.

5. The de-palletizing carousel logistics equipment of claim 1, wherein, The conveying mechanism comprises a roller (13) driven by a roller driving motor (14), and the roller (13) is configured to be temporarily operated when the safety detection fails to pass, so as to drive the target pallet to adjust the pose by friction.

6. A method of palletizing using the depalletizing logistics equipment according to any one of claims 1 to 5, characterized in that, The method comprises: Controlling the conveying mechanism to convey the first to-be-stacked material to the position directly below the equipment; Controlling the subsequent to-be-stacked material to pause before being conveyed to the position below the equipment; Based on the material information identified by the series of detection elements (16), controlling the fork structure (3) to fork the bottommost pallet in the material in place and lift it; Controlling the subsequent to-be-stacked material to be conveyed to the position below the lifting space; Controlling the fork structure (3) to place the forked material on the subsequent to-be-stacked material; Repeating the above steps to stack layer by layer.

7. The method of claim 6, wherein, When the to-be-stacked material contains a mother pallet (22), in the final stage of stacking, controlling the fork structure (3) to lift all the stacked materials as a whole, conveying the mother pallet (22) to the position below it, and then placing the materials on the mother pallet (22).

8. A method of de-palletizing using the de-palletizing system of any one of claims 1 to 5, wherein, The method comprises: Based on the material pile (2) information obtained by the series of detection elements (16), determining the target pallet; Controlling the lifting structure to drive the fork structure (3) to ascend or descend to the target pallet position; Based on the feedback of the fork mechanism detection assembly, controlling the fork structure (3) to perform the forking operation; Controlling the fork taking structure (3) to take the target pallet; Controlling the conveying mechanism to transport the bottom layer material out; Repeating the above steps to disassemble the material pile (2) layer by layer.

9. The method of claim 8, wherein, The step of controlling the fork taking structure (3) to perform the fork taking operation comprises: when the safety detection is not connected, generating a pose adjustment instruction to control the conveying mechanism to run adjustment to correct the pose of the target pallet through friction.

10. The method of claim 8, wherein, During the disassembly process, whether to supplement the mother pallet (22) for the disassembled material is dynamically determined according to whether the initial material pile (2) bottom exists the mother pallet (22) and the order demand.

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