Whole-tray automatic loading system and loading equipment for realizing same

Abstract

The invention relates to the technical field of intelligent logistics, and discloses a whole-tray automatic truck loading system and truck loading equipment for realizing the system.The whole-tray automatic truck loading system comprises a warehouse management system, an automatic equipment management system, a laser-guided stacking forward-moving type automatic guided vehicle, a truck parking posture detection device and an automatic guided vehicle dispatching system. A warehouse management system is used for receiving a transfer order and carrying out stock-up and storage location distribution, a carrying task is generated in combination with an automatic guided vehicle dispatching system, and a laser-guided stacking forward-moving type automatic guided vehicle forks two whole-tray cargoes in a workshop in a laser navigation mode at a time and carries the cargoes to a ground cache area. Natural navigation and laser ranging positioning are carried out in the compartment, the continuous process of automatic loading of the whole tray is achieved, the loading operation efficiency is improved, and the manual forklift operation time is shortened.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent logistics, in particular to a whole pallet automatic loading system and a loading equipment for realizing the system. BACKGROUND

[0002] In the field of logistics storage and cargo transfer, whole pallet cargo loading is a key link connecting storage and terminal distribution, and the continuity and efficiency of its operation process directly affect the overall operation efficiency of the logistics link. With the increasing demand for bulk material transfer in the logistics industry, the whole pallet cargo loading operation continues to increase, and the automation and precision of the loading technology are increasingly urgent.

[0003] At present, the traditional technical solution for whole pallet cargo loading is "manual allocation of storage location + manual driving of forklift handling". During operation, the staff first receives the transfer order through the warehouse management system, manually records the storage location information of the material and coordinates the preparation of goods; then the forklift driver drives the forklift to the specified storage location to pick up a single whole pallet cargo according to the manually transmitted storage location and loading requirements, and then drives to the side of the truck to complete the loading. The whole process needs manual monitoring of the storage location state, forklift driving path and cargo loading position, and only one whole pallet cargo can be handled at a time.

[0004] However, the present inventors found at least the following technical problems in the process of implementing the technical solution of the present application: in the traditional technical solution, the allocation of storage location and the handling operation of forklift lack automation cooperation, the forklift can only pick up one whole pallet cargo at a time, and the path planning and loading operation rely on manual intervention, resulting in broken loading process and low operation efficiency, long time occupation of manual forklift operation, and inability to meet the demand for rapid transfer of bulk materials. SUMMARY

[0005] In view of the deficiencies of the prior art, the present application provides a whole pallet automatic loading system and a loading equipment for realizing the system, which solves the problem of lack of automation cooperation between the allocation of storage location and the handling operation of forklift in the traditional technical solution, the forklift can only pick up one whole pallet cargo at a time, and the path planning and loading operation rely on manual intervention, resulting in broken loading process and low operation efficiency.

[0006] To achieve the above purpose, the present application is realized by the following technical solution: a whole pallet automatic loading system, comprising a warehouse management system, an automatic equipment management system, a laser-guided stacking forward automatic guided vehicle, a truck parking pose detection device and an automatic guided vehicle scheduling system, the system achieves whole pallet automatic loading according to the following steps:

[0007] S1, the warehouse management system receives the transfer order and allocates the storage location, and synchronizes the allocated storage location state to the automatic equipment management system;

[0008] S2, after the truck stops at the platform, the truck parking pose detection device detects the truck model length and lateral offset in real time, and uploads the detection result to the automatic guided vehicle scheduling system;

[0009] S3, the automatic guided vehicle scheduling system generates an automatic guided vehicle handling task according to the transfer order, the ready-to-ship storage location and the truck parking pose, and issues the task;

[0010] S4, after the laser-guided stacker front-moving type automatic guided vehicle receives the task, it runs to the warehouse outlet in the workshop using laser navigation and natural navigation mode, and forks two whole pallets of goods at a time;

[0011] S5, the laser-guided stacker front-moving type automatic guided vehicle carries the forked two whole pallets of goods to the ground buffer area, and after completing the manual / automatic packing machine packing, the warehouse management system receives the packing completion confirmation signal;

[0012] S6, the warehouse management system issues a loading task to the automatic guided vehicle scheduling system, and the laser-guided stacker front-moving type automatic guided vehicle takes goods from the ground buffer area and enters the truck compartment, then switches to natural navigation and laser navigation mode, and loads goods according to the planned path / automatically assigned path until the loading is completed;

[0013] S7, after the loading is completed, the laser-guided stacker front-moving type automatic guided vehicle drives out of the truck compartment, the loading bridge is automatically retracted, the truck locking device is released, and the truck drives away.

[0014] Preferably, the process of S1 in which the warehouse management system receives the transfer order and performs the ready-to-ship storage location allocation includes: importing or adding the transfer order, selecting the platform, adding the tobacco material details, the sum of the piece numbers corresponding to the box numbers of each detail is not greater than the maximum load of the vehicle, and after submission, the transfer order is executed to allocate the ready-to-ship storage location, and the storage location state is displayed in real time on the large screen page as allocated.

[0015] Preferably, the process of S2 in which the truck parking pose detection device detects the truck model length and lateral offset in real time includes: a top camera collects a truck side image, and calculates the truck length through image processing;

[0016] The safety laser radars on both sides of the platform measure the distance from the left and right side walls of the truck compartment, calculate the lateral offset in combination with the standard truck width, and upload the detection result to the automatic guided vehicle scheduling system for path compensation.

[0017] Preferably, the process of the automatic guided vehicle scheduling system in S3 generating and issuing the automatic guided vehicle handling task according to the transfer order, the standby goods storage location and the truck parking pose includes: receiving the transfer order and the standby goods storage location information issued by the warehouse management system, combining the truck model length and the lateral offset uploaded by the truck parking pose detection device, calculating the optimal loading path, generating the handling task, and issuing it to the laser-guided stacker-lead automatic guided vehicle through the wireless local area network.

[0018] Preferably, the process of the laser-guided stacker-lead automatic guided vehicle running to the warehouse outlet in the workshop in S4 includes: arranging a reflector plate at a fixed position in the workshop, the laser-guided stacker-lead automatic guided vehicle real-time scans at least four reflector plates through the laser scanner, calculates the distance and angle with the reflector plate, iteratively solves the position and heading angle in the global coordinate system, and reaches the positioning and running to the warehouse outlet along the planned path.

[0019] Preferably, the process of the laser-guided stacker-lead automatic guided vehicle handling the two whole pallet goods forked to the ground buffer area and completing the manual / automatic packing machine packing in S5 includes: the laser-guided stacker-lead automatic guided vehicle forks two whole pallet goods at the warehouse outlet once, runs to the ground buffer area to unload goods along the laser navigation path, the ground buffer area is provided with eighteen storage locations, the front-to-back and left-to-right spacing between the storage locations is 1000mm, after manual packing is completed at the ground buffer area, the packing completion is confirmed through the mobile terminal, and the confirmation signal is uploaded to the warehouse management system.

[0020] Preferably, the process of the laser-guided stacker-lead automatic guided vehicle switching to natural navigation and laser positioning navigation mode after entering the truck compartment in S6 includes: after the laser-guided stacker-lead automatic guided vehicle enters the truck compartment, the laser scanner switches to the natural navigation mode, real-time scans the vehicle compartment wall point cloud to construct a local map, calculates the real-time position in the vehicle compartment through the inter-frame point cloud matching and pose graph optimization, loads the goods according to the dynamically planned loading path, loads two piles per row each time, and until the whole vehicle is loaded, the laser ranging positioning component starts the laser navigation to review the natural navigation data.

[0021] Preferably, the system further includes a safety laser grading protection mechanism, which real-time scans the surrounding environment below the vehicle head, fork leg and gantry during the whole process of the laser-guided stacker-lead automatic guided vehicle running and loading, divides the emergency stop area, the buffer area and the safety area, and stops immediately when the obstacle enters the emergency stop area, slows down when entering the buffer area, and further slows down when entering the safety area.

[0022] Preferably, the system further comprises an automatic charging control strategy, when the battery power of the laser-guided stacker-advanced AGV is less than 30%, it directly navigates to the charging pile for charging when there is no task, or it goes to the charging pile after completing the current task when it is executing a task, and returns to the rest position after charging to a power level of not less than 90%.

[0023] Preferably, the loading device of the whole pallet automatic loading system is a laser-guided stacker-advanced AGV, which comprises a laser scanner, a safety laser radar, a fork mechanism, a vehicle-mounted controller and a wireless communication module.

[0024] Working principle: first, the warehouse management system receives the transfer order and allocates the standby loading position, after the truck stops at the platform, the truck parking pose detection device detects the length and lateral offset of the truck through the top camera and the safety laser radar on both sides of the platform and uploads it to the AGV scheduling system, the AGV scheduling system generates a carrying task according to the transfer order, standby loading position and truck parking pose and issues it. Secondly, the laser-guided stacker-advanced AGV uses laser navigation in the workshop, calculates its position by real-time scanning of the reflector, runs to the loading port to pick up two whole pallets and carries them to the ground buffer area, and the worker completes the packaging in the ground buffer area and confirms it through the mobile terminal. The warehouse management system receives the confirmation signal and issues the loading task. Finally, the laser-guided stacker-advanced AGV takes the goods from the ground buffer area, switches to natural navigation mode after entering the truck compartment, constructs a local map by scanning the point cloud of the compartment wall and loads the goods according to the planned path, and drives out of the compartment after loading is completed. The loading bridge is automatically retracted, the lock is released, and the truck drives away.

[0025] The application provides a whole pallet automatic loading system and a loading device for realizing the system.

[0026] 1. The application realizes the continuous process of whole pallet automatic loading by receiving the transfer order through the warehouse management system, allocating the standby loading position, generating the carrying task by the AGV scheduling system, and picking up two whole pallets in the workshop by the laser-guided stacker-advanced AGV using laser navigation, which improves the loading efficiency and reduces the manual forklift operation time.

[0027] 2. The laser-guided stacker-advanced AGV switches to natural navigation mode after entering the truck compartment, constructs a local map by real-time scanning of the point cloud of the compartment wall, optimizes the real-time position by pose graph, loads the goods according to the dynamic planning path, which improves the loading accuracy and adaptability and reduces the risk of goods damage.

[0028] 3、The application is equipped with a safe laser grading protection mechanism, which divides the emergency stop area, buffer area and safety area during the operation of the laser-guided stacker front-moving type automatic guided vehicle, adjusts the speed in real time according to the distance of the obstacle, and monitors the battery power and navigates to the charging pile through the automatic charging control strategy, so as to ensure the stable operation of the system and improve the operation safety. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 It is an information collection interface schematic diagram of the application;

[0030] Figure 2 It is a PAD interface schematic diagram of the application;

[0031] Figure 3 It is a software interface schematic diagram of the application;

[0032] Figure 4 It is a local structure schematic diagram of the laser-guided stacker front-moving type automatic guided vehicle of the application;

[0033] Figure 5 It is a local structure schematic diagram of the vehicle-mounted controller of the application.

[0034] 1, laser-guided stacker front-moving type automatic guided vehicle; 101, laser scanner; 102, safety laser radar; 103, fork mechanism; 104, vehicle-mounted controller; 105, wireless communication module. DETAILED DESCRIPTION

[0035] The technical solutions of the application will be described clearly and completely below in combination with the drawings of the application. Obviously, the described embodiments are only some of the embodiments of the application, not all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the application.

[0036] Please refer to the drawings of the application Figures 1-5 The embodiment of the application provides a whole pallet automatic loading system, which comprises a warehouse management system, an automatic equipment management system, a laser-guided stacker front-moving type automatic guided vehicle 1, a truck parking pose detection device and an automatic guided vehicle scheduling system. The system reaches the whole pallet automatic loading according to the following steps:

[0037] S1, the warehouse management system receives the transfer order and allocates the warehouse, and synchronizes the state of the allocated warehouse to the automatic equipment management system;

[0038] S2, after the truck parks on the platform, the truck parking pose detection device detects the length and lateral offset of the truck in real time, and uploads the detection result to the automatic guided vehicle scheduling system;

[0039] S3, the automatic guided vehicle scheduling system generates an automatic guided vehicle handling task according to the transfer order, the standby goods storage location and the truck parking pose, and issues the task;

[0040] S4, after receiving the task, the laser-guided stacker AGV 1 runs to the warehouse exit using laser navigation and natural navigation, and forks two full pallets of goods at a time;

[0041] S5, the laser-guided stacker AGV 1 carries the forked two full pallets of goods to the ground buffer area, and after completing the manual / automatic packing machine packing, the warehouse management system receives the packing completion confirmation signal;

[0042] S6, the warehouse management system issues a truck loading task to the automatic guided vehicle scheduling system, the laser-guided stacker AGV 1 takes goods from the ground buffer area and switches to natural navigation and laser navigation after entering the truck compartment, and loads goods row by row according to the planned path / automatically assigned path until the truck loading is completed;

[0043] S7, after the truck loading is completed, the laser-guided stacker AGV 1 drives out of the truck compartment, the loading bridge is automatically retracted, the truck locking device is released, and the truck drives away.

[0044] Specifically, the warehouse management system is connected to the upstream system through a WebService interface, receives transfer order data, and communicates with the automated equipment management system through a local area network to synchronize the status of the storage location.

[0045] The automated equipment management system and the automatic guided vehicle scheduling system are connected through a wireless local area network, the laser-guided stacker AGV 1 includes a laser scanner, a safety laser radar, a fork mechanism, a vehicle-mounted controller and a wireless communication module, the vehicle-mounted controller receives task instructions issued by the automatic guided vehicle scheduling system through the wireless local area network, and controls the drive wheels and the fork mechanism of the laser-guided stacker AGV 1 to perform the handling task.

[0046] The truck parking pose detection device includes a top camera and safety laser radars on both sides of the platform, and uploads the detection data to the automatic guided vehicle scheduling system through a wired connection. The automatic guided vehicle scheduling system includes a task management module, a vehicle management module, a traffic management module and a communication interface module, and exchanges data with the warehouse management system, the automated equipment management system and the laser-guided stacker AGV 1 through the communication interface module.

[0047] In S1, after receiving the transfer order, the warehouse management system performs standby goods allocation and updates the storage location occupation information to the large screen display page through the automated equipment management system.

[0048] In S2, the truck parking pose detection device collects data, and the AGV scheduling system receives the truck length and lateral offset for subsequent path compensation.

[0049] In S3, the AGV scheduling system integrates the transfer sheet, the ready-to-pick location, and the truck parking pose data to generate a carrying task, which is sent to the laser-guided AGV 1 through a wireless local area network.

[0050] In S4, the laser-guided AGV 1 operates in the warehouse using laser navigation, with n reflective plates arranged in the warehouse, where n is greater than or equal to 3. The laser scanner obtains the distance and the angle between the laser scanner and the i-th reflective plate, where i is the reflective plate number, to calculate the position of the laser-guided AGV 1.

[0051] The laser navigation positioning calculation is as follows: the coordinates of the i-th reflective plate in the global coordinate system are , the position of the laser-guided AGV 1 in the global coordinate system is (x, y), the heading angle is , and the coordinates of the reflective plate in the sensor coordinate system are:

[0052] , ; (41)

[0053] The error equation set is constructed as follows:

[0054] ; (42)

[0055] The error vector is: ; (43)

[0056] The cost function is minimized as follows: ; (44)

[0057] The Levenberg-Marquardt iteration is used to solve the pose where is the Hessian matrix, is the Jacobian matrix of , and is the damping coefficient.

[0058] The iterative update formula is: ; (45)

[0059] In S5, the laser-guided AGV 1 unloads the goods to the ground buffer area, which contains 18 locations with a front-to-back and left-to-right spacing of 1000mm. After packaging, the mobile terminal uploads a confirmation signal to the warehouse management system.

[0060] In S6, after the laser-guided stacking advance automated guided vehicle 1 enters the freight car, it switches to natural navigation mode, and the laser scanner collects point clouds from the car wall. ;

[0061] The previous frame point cloud is .

[0062] Solving rigid body transformations using the iterative nearest point algorithm , minimize:

[0063] (61)

[0064] Construct a pose graph, where nodes represent poses. The edges are constraints The error is The total cost is:

[0065] (62)

[0066] Minimize using Gauss-Newton method .

[0067] The laser-guided stacking advance automated guided vehicle 1 loads goods row by row according to the planned path, loading two stacks of goods in one row each time.

[0068] exist In the process, after the laser-guided stacking advance automated guided vehicle 1 departs, the loading ramp retracts via a control signal, and the locking device is released via a mechanical mechanism. During system operation, the laser-guided stacking advance automated guided vehicle 1 is equipped with a safety laser radar to delineate an emergency stop zone (radius). ), buffer and safe zone When the obstacle enters the emergency stop zone, it stops; when it enters the buffer zone, it decelerates to a stop. Slow down when entering the safe zone Speed ​​control is ,in According to the region definition.

[0069] Laser-guided stacking forward automated guided vehicle 1 Battery power Below When there is no task, it navigates to a charging station; when a task is being performed, it charges to a charging station after completing the task. Not less than .

[0070] charging pile contact deviation ,error Then plug it in to charge.

[0071] System path planning adopts algorithm, grid map , cost , wherein ; in speed planning, the maximum speed , acceleration , acceleration distance .

[0072] Further, the process of receiving the transfer order and allocating the storage location by the warehouse management system in S1 includes: importing or adding the transfer order, selecting the platform, adding the tobacco material details, the sum of the piece number corresponding to each detail box number is not greater than the maximum vehicle load, after submission, the transfer order is executed to allocate the storage location, and the storage location state is displayed in real time on the large screen page as allocated.

[0073] Specifically, the transfer order data structure includes transfer order number, platform number, vehicle type, vehicle maximum load and material detail list, the material detail list is in array form, each item includes material code, material name, box number and corresponding piece number.

[0074] The warehouse management system realizes the import of the transfer order through the file upload interface, the file format is CSV or Excel, the system parses the file content, extracts the transfer order number and the material detail list, and stores them in the database table.

[0075] For the added transfer order, the warehouse management system provides a user interface, after selecting the platform number, the system queries the available platform list from the database, and the platform list includes the platform number, the current occupation state and the vehicle type.

[0076] When adding the tobacco material details, the system queries the tobacco material code and name from the material information table, the user inputs the box number, the system automatically calculates the corresponding piece number, and the calculation formula is: piece number = box number x single box piece number, wherein the single box piece number is the pre-stored value in the material information table.

[0077] The system checks the total sum of the piece numbers of all details, and the total sum calculation formula is: , wherein, is the detail item serial number, is the total number of detail items, and when the total piece number > the maximum vehicle load, the system returns an error message and prevents submission.

[0078] After the submission of the transfer order, the warehouse management system inserts the transfer order data into the database and triggers the goods preparation allocation bin operation. The goods preparation allocation algorithm selects an idle bin from the available bin list, which contains bin numbers, capacities, and current occupancy. The allocation principle is to prefer bins with an occupancy of 0. After allocation is complete, the warehouse management system updates the bin status to allocated and pushes the updated data to the automated equipment management system via an HTTP interface. After receiving the updated data, the automated equipment management system sends the bin status in real-time to the large screen page via a WebSocket connection. The large screen page uses JavaScript to parse the data and changes the corresponding bin color and text display to allocated. The warehouse management system logs the goods preparation allocation process, and the log format is [timestamp] [operation type] [transfer order number] [bin number] [result code]. A result code of 0 indicates success.

[0079] Further, the process of detecting the truck model length and lateral offset by the truck parking pose detection device in S2 includes: the top camera captures the truck silhouette image, and calculates the truck length through image processing;

[0080] The safety laser radars 102 on both sides of the platform measure the distance of the left and right side walls of the truck compartment, calculate the lateral offset in combination with the standard truck width, and upload the detection results to the automated guided vehicle dispatching system for path compensation.

[0081] Specifically, the truck parking pose detection device is deployed in the platform area, and the top camera is installed above the platform to capture the truck silhouette image After that, the system performs grayscale conversion to convert the image into a single-channel grayscale image , wherein , is the pixel channel value of the original image, and the system applies Cannyi edge detection to the grayscale image , sets the low threshold and the high threshold , and extracts the truck contour line segment.

[0082] The system identifies the horizontal pixel length of the truck head to the tail in the contour , calculates the actual length of the truck in combination with the camera calibration coefficient : ; wherein is obtained by measuring the calibration board. The system supports 9.6-meter and 13.6-meter models. When the calculation is within the range of 9.6 meters, it is determined to be a 9.6-meter model, and when it is within the range of 13.6 meters, it is determined to be a 13.6-meter model.

[0083] The safety laser radars on both sides of the platform are installed at the edge of the platform with a scanning angle of The measurement resolution is 0.01 meters. The left-side lidar measures the distance to the left side wall of the carriage. The right-side lidar measures the distance to the right side wall of the carriage. The system queries the database for standard vehicle width. Calculate the lateral offset: .

[0084] The system calculates the longitudinal offset. The measurement is performed by aligning the rear of the vehicle with the locking device's baseline. The baseline position is pre-stored in the system configuration file, and the detection result data packet includes the vehicle's length. Lateral offset and vertical offset ,pass The protocol is uploaded to the automated guided vehicle (AGV) dispatching system. After receiving the data, the AGV dispatching system will... Applied to path compensation, the compensation formula is for adjusting the coordinates of path points:

[0085] ;

[0086] in, and The system log records the detection process, using the coordinates of the original planned path points. The log format is [timestamp [platform number] [vehicle type length] [lateral offset] [result code]. A result code of 0 indicates successful upload. The truck parking posture detection device is connected to the automated guided vehicle dispatching system via wired Ethernet.

[0087] Furthermore, the process by which the automated guided vehicle (AGV) dispatching system in S3 generates and issues AGV handling tasks based on the transfer order, the warehouse location, and the truck's parking position includes: receiving the transfer order and warehouse location information issued by the warehouse management system, combining the vehicle length and lateral offset uploaded by the truck parking position detection device, calculating the optimal loading path, generating the handling task, and issuing it to the laser-guided stacking forward AGV 1 via the wireless local area network.

[0088] Specifically, the automated guided vehicle (AGV) dispatching system receives transfer order data from the warehouse management system through the communication interface module. The transfer order data includes the transfer order number, material details list, inventory location number, and platform number. The data format is JSON object, and it is transmitted via the WebService protocol.

[0089] The automated guided vehicle (AGV) dispatching system simultaneously receives vehicle length data from the truck parking position detection device. Lateral offset and vertical offset Data is uploaded in binary packets via the TCPP protocol. Each packet is 28 bytes in size and contains a checksum field for data integrity verification.

[0090] The vehicle management module queries the current state of the laser-guided stacker AGV 1, including position, power and idle flag, from the database vehicle state table, which contains vehicle number, current position coordinates Power and status code.

[0091] The task management module integrates the transfer order, warehouse preparation location and truck parking pose data, and sorts them in chronological order and priority. The priority The calculation formula is:

[0092] ;

[0093] Wherein, is the preset weight, the task urgency is extracted from the transfer order, and the value is an integer from 0 to 10.

[0094] The traffic management module checks path conflicts, uses semaphore to control road segment access, the value is 0 or 1, when is 0 and there is no higher priority vehicle reservation, the road segment is assigned. The path planning uses algorithm, the workshop map is divided into grids , each grid size is 0.5 meters , the state is free, occupied or forbidden. In the algorithm, the cost function of node is: ;

[0095] Wherein, is the actual path cost from the starting point to , and is the estimated distance to the target, calculated as ; wherein, is the node coordinate, is the target coordinate.

[0096] The path planning considers truck parking pose compensation, adjusts the path point coordinates to , wherein, is the non-offset path point. After generating the carrying task, the task data structure contains task number, starting point coordinates, end point coordinates, path point list and vehicle number, which is issued through wireless local area network. The wireless communication module of the laser-guided stacker AGV 1 receives the task and returns an acknowledgement signal. The signal format is task number][result code], and the result code is 0, indicating successful reception.

[0097] The automatic guided vehicle scheduling system log record task generation and delivery process, the log format is [timestamp][task number][vehicle number][path length][result code], the path length unit is meters, the result code is 0, indicating that the delivery is successful, the automatic guided vehicle scheduling system database stores task history, the table structure includes task number, generation time, delivery time and execution state, for subsequent query and audit.

[0098] Further, the process of the laser-guided stacker- forward automatic guided vehicle 1 running to the warehouse outlet in the workshop in the laser navigation mode in S4 includes: arranging reflective plates at fixed positions in the workshop, the laser-guided stacker-forward automatic guided vehicle 1 scans at least four reflective plates in real time through the laser scanner 101, calculates the distance and angle with the reflective plates, iteratively solves the position and heading angle of itself in the global coordinate system, and reaches positioning and running to the warehouse outlet along the planned path.

[0099] Specifically, the workshop is arranged four reflective plates, greater than or equal to 3, the reflective plates are installed at fixed positions, the surface reflectivity of the reflective plates is 0.9, and the distance between the reflective plates is 5-10 meters, so as to ensure that the laser-guided stacker-forward automatic guided vehicle 1 scans at least four reflective plates at any position.

[0100] The laser scanner 101 is installed on the top of the laser-guided stacker-forward automatic guided vehicle 1, the scanning angle is 360 degrees, the laser scanner 101 emits a laser beam and receives the reflected signal of the reflective plate, calculates the distance of the i-th reflective plate and the angle relative to the axis of the sensor coordinate system, where i is the serial number of the reflective plate.

[0101] The vehicle-mounted controller establishes a global coordinate system , and the coordinates of the reflective plates in the global coordinate system are These coordinates are pre-stored in the map file of the laser-guided stacker-forward automatic guided vehicle 1, the map file format is XML, and includes the reflective plate D and the coordinate pair. The coordinate calculation formula of the laser-guided stacker-forward automatic guided vehicle 1 in the sensor coordinate system is (41), and the coordinate transformation equation constructed by the vehicle-mounted controller is (42), wherein is the position of the laser-guided stacker-forward automatic guided vehicle 1 in the global coordinate system, is the heading angle. The error vector definition formula is (43), the vehicle-mounted controller minimizes the cost function (44), iteratively solves using the Levenberg-Marquardt algorithm, and the Hessian matrix is ; the iterative update formula is (45).

[0102] The upper limit of the number of iterations is 50 times, and the convergence threshold is 0.001 meters. After obtaining the pose, the vehicle-mounted controller controls the driving wheel to run along the planned path, and the path point interval is 0.2 meters. The exit is transformed into a combination of chain line and roller line. The first exit retains the rotating table and the roller line, and the roller line is replaced with a chain line. The chain line and the rotating table use a jacking and shifting roller device. The second exit is lengthened, and the fork picking direction is perpendicular to the chain line direction to ensure that the laser-guided stacker AGV 1 fork mechanism picks up two whole pallets of goods at a time. The vehicle-mounted controller sends control signals to the fork mechanism hydraulic pump through the CAN bus. The laser-guided stacker AGV 1 records the navigation process in the log. The log format is [timestamp] [position x, y] [heading angle] [number of scanned reflectors] [result code], and the result code is 0, indicating successful positioning.

[0103] Further, the process of the laser-guided stacker AGV 1 transporting the two whole pallets of goods to the ground buffer area and completing the manual packing / automatic packing machine packing in S5 includes: the laser-guided stacker AGV 1 picks up two whole pallets of goods at the exit, runs along the laser navigation path to the ground buffer area to unload the goods, and the ground buffer area is provided with eighteen storage locations with a front-to-back and left-to-right spacing of 1000mm. After manual packing is completed at the ground buffer area, the mobile terminal confirms that the packing is complete, and the confirmation signal is uploaded to the warehouse management system.

[0104] Specifically, after the laser-guided stacker AGV 1 is positioned at the exit, the vehicle-mounted controller sends a signal to the fork mechanism, the fork is inserted into the bottom of the two whole pallets of goods, the pallet size is standard 1200mm x 1000mm, and the picking gap is 80mm. After picking is completed, the hydraulic system lifts the goods by 0.3 meters, and the vehicle-mounted controller calculates the path from the exit to the ground buffer area using laser navigation. The ground buffer area is located on the ground in the workshop and includes 18 storage locations, each with an area of 2m x 2m and a front-to-back and left-to-right spacing of 1000mm to ensure manual operation space. After the laser-guided stacker AGV 1 reaches the designated storage location, the fork is lowered to a ground height of 0.1 meters, and the goods are unloaded.

[0105] Manual packing uses a manual packing machine. After wrapping the goods, the mobile terminal APP scans the storage location QR code, the APP interface displays the transfer order number and the packing button, the user clicks to confirm, generates a confirmation signal, the signal format is a JSON object, and includes the transfer order number, storage location number and confirmation timestamp. The mobile terminal uploads the confirmation signal to the warehouse management system through a wireless local area network, the upload protocol is HTTPS, data encryption uses AES-128, and the warehouse management system updates the database transfer order status to "packing complete" after receiving the signal, and notifies the automatic guided vehicle scheduling system to prepare to issue a loading task. ​

[0106] The laser-guided stack-pushing AGV 1 logs the loading process in the format of [timestamp] [start position] [end position] [number of stacks] [result code], where the result code is 0 indicating successful loading.

[0107] Further, the process of switching to natural navigation and laser positioning navigation mode after the laser-guided stack-pushing AGV 1 enters the truck compartment in S6 includes: after the laser-guided stack-pushing AGV 1 enters the truck compartment, the laser scanner 101 switches to natural navigation mode, scans the compartment wall point cloud in real time to construct a local map, calculates the real-time position in the compartment through inter-frame point cloud matching and pose graph optimization, loads the goods row by row according to the dynamic planning loading path, loads two stacks per row each time, and the laser ranging positioning component starts laser navigation to review the natural navigation data until the whole truck is loaded.

[0108] Specifically, the laser-guided stack-pushing AGV 1 enters the truck compartment through the loading bridge, the width of the loading bridge is 2 meters, and after entering, the vehicle-mounted controller detects the compartment entrance mark and switches the laser scanner 101 to natural navigation mode.

[0109] The laser scanner 101 scans the compartment wall at a frequency of 10 Hz to collect the current frame point cloud. The inter-frame matching uses the iterative closest point algorithm to solve the rigid body transformation , the minimization uses formula (61), the nearest neighbor is searched through the KD tree, and the upper limit of the number of iterations is 20 times.

[0110] The pose graph node is the pose The edge is the constraint , and the error is: ; the total cost is formula (62), and the Gauss-Newton method is used for minimization , the Jacobian matrix is calculated by numerical differentiation, and the optimization step is 0.1. The dynamic planning loading path is based on the length of the truck, and the path point number of a 9.6-meter truck is 50 points, and the path point number of a 13.6-meter truck is 70 points. The path adjustment considers the offset and .

[0111] Each time, one row of two stacks of goods is loaded, and the unloading height decreases by 0.5 meters per row. After the whole truck is loaded, the vehicle-mounted controller sends a completion signal to the AGV scheduling system, and the laser-guided stack-pushing AGV 1 logs the loading process in the format of [timestamp] [current pose [loading row number] [result code], where the result code is 0 indicating successful loading.

[0112] ​Furthermore, the system also includes a safety laser graded protection mechanism. During the entire operation and loading process of the laser-guided stacking forward automated guided vehicle 1, the safety lasers configured under the front, forks, and mast scan the surrounding environment in real time, dividing it into emergency stop zone, buffer zone, and safe zone. When an obstacle enters the emergency stop zone, the vehicle stops immediately; when it enters the buffer zone, the vehicle decelerates; and when it enters the safe zone, the vehicle decelerates further.

[0113] Specifically, the laser-guided stacking advance automated guided vehicle (AGV1) is equipped with four safety laser radars: one at the front scanning 180 degrees forward, two on the forks scanning 90 degrees to the sides, and one under the gantry scanning 120 degrees downward. The emergency stop zone radius is [not specified]. meters, buffer zone is meters, the safe zone is These radii are pre-stored in the vehicle controller configuration file and can be adjusted through the software interface.

[0114] The vehicle controller calculates the distance to obstacles in real time. ,

[0115] when The drive wheels are stopped by cutting off the power supply from the side.

[0116] when Then reduce the speed to ,

[0117] when Then reduce the speed to The speed output is calculated as follows:

[0118] ;

[0119] in, For reference speed, The safety lidar is connected to the vehicle controller via a PLC interface. Triggered events are recorded in the log in the format of [timestamp][area type][obstacle distance r][speed adjustment][result code]. A result code of 0 indicates successful processing.

[0120] Furthermore, the system also includes an automatic charging control strategy. When the battery level of the laser-guided stacking automated guided vehicle 1 is below 30%, if there is no task, it will directly navigate to the charging station to charge; if a task is being performed, it will proceed to the charging station after completing the current task, and return to the resting position after charging to a level of at least 90%.

[0121] Specifically, the laser-guided stacking forward automated guided vehicle (AGV) has one battery. The vehicle controller checks the battery status every 10 seconds for lithium iron phosphate batteries. The unit is percentage.

[0122] when And the vehicle management module query task queue is empty, the vehicle controller generates a charging task, the starting point is the current location, and the endpoint is the charging pile coordinate , the charging pile coordinate is pre-stored in the map file. When and there is a current task, the vehicle is marked as not assignable to a new task, and the charging path navigation is performed after the current task is completed. The laser navigation is used for navigation to the charging pile, the traffic control is considered in path planning, and the contact deviation is adjusted after arrival: When , the charging brush head is inserted, the charging mode is side charging, and the charging time is 2 hours.

[0123] During the charging process, the vehicle controller monitors , , the brush head is pulled out, and the navigation is performed to the rest position coordinate The automatic charging control strategy log record is [timestamp][power][charging starting point][charging duration][result code], the result code is 0, indicating that the charging is completed, and the vehicle controller reports the charging state to the automatic guided vehicle scheduling system through a wireless local area network.

[0124] An automatic loading equipment of a whole pallet automatic loading system, the automatic loading equipment is a laser-guided stack forward automatic guided vehicle 1, comprising a laser scanner 101, a safety laser radar 102, a fork mechanism 103, a vehicle controller 104 and a wireless communication module 105.

[0125] Although the embodiments of the present application have been shown and described, it can be understood by those of ordinary skill in the art that various changes, modifications, replacements and variations can be made to the embodiments without departing from the principles and spirits of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. An automated pallet loading system, characterized in that, The system includes a warehouse management system, an automated equipment management system, a laser-guided stacking advance automated guided vehicle (1), a truck parking posture detection device, and an automated guided vehicle scheduling system. The system achieves automatic loading of the entire pallet by following these steps: S1. The warehouse management system receives transfer orders, prepares goods, allocates storage locations, and synchronizes the status of the allocated storage locations to the automated equipment management system. S2. After the freight car stops at the platform, the freight car stopping posture detection device detects the length and lateral offset of the freight car model in real time, and uploads the detection results to the automated guided vehicle dispatching system. S3. The automated guided vehicle (AGV) dispatching system generates and issues AGV handling tasks based on the transfer order, the warehouse location, and the truck's parking position. S4, Laser-guided stacking forward automatic guide vehicle (1) After receiving the task, it runs to the warehouse exit in the workshop using laser navigation and natural navigation, and picks up two whole pallets of goods at a time. S5, Laser-guided stacking forward automatic guide vehicle (1) transports two full pallets of goods picked up by forks to the ground buffer area. After the manual / automatic packing machine is completed, the warehouse management system receives the packing completion confirmation signal. S6. The warehouse management system sends the loading task to the automated guided vehicle scheduling system. The laser-guided stacking forward automated guided vehicle (1) picks up the goods from the ground buffer area, enters the truck compartment, and switches to natural navigation and laser navigation mode. It loads the goods row by row according to the planned path / automatic allocation path until the loading is completed. S7. After loading is completed, the laser-guided stacking forward automatic guided vehicle (1) drives out of the truck compartment, the loading bridge automatically retracts, the locking device is released, and the truck drives away.

2. The automatic pallet loading system according to claim 1, characterized in that, The process of receiving transfer orders and preparing and allocating storage locations in the S1 warehouse management system includes: importing or adding transfer orders, selecting a platform, adding material details, ensuring that the sum of the number of pieces corresponding to the number of boxes in each detail does not exceed the maximum carrying capacity of the vehicle, and then performing the preparation and allocation of storage locations for the transfer orders. The storage location status is displayed in real time on the large screen as allocated.

3. The automatic pallet loading system according to claim 2, characterized in that, The process of the truck parking posture detection device in S2 to detect the truck model length and lateral offset in real time includes: the top camera acquires the side image of the truck, and the truck length is calculated through image processing; Safety lidar (102) on both sides of the platform measures the distance between the left and right walls of the carriage, respectively, and calculates the lateral offset based on the standard carriage width. The detection results are uploaded to the automated guided vehicle scheduling system for path compensation.

4. The automatic pallet loading system according to claim 3, characterized in that, The process of generating and issuing automated guided vehicle (AGV) handling tasks based on transfer orders, warehouse locations, and truck parking positions in S3 includes: receiving transfer orders and warehouse location information from the warehouse management system, combining the vehicle length and lateral offset uploaded by the truck parking position detection device, calculating the optimal loading path, generating handling tasks, and issuing them to the laser-guided stacking forward AGV via wireless local area network (1).

5. The automatic pallet loading system according to claim 4, characterized in that, The process of the laser-guided stacking forward automatic guided vehicle (1) in S4 running to the exit of the warehouse using laser navigation in the workshop includes: placing reflectors at fixed positions in the workshop, the laser-guided stacking forward automatic guided vehicle (1) scanning at least four reflectors in real time through a laser scanner (101), calculating the distance and angle with the reflectors, iteratively solving its own position and heading angle in the global coordinate system, achieving positioning and running to the exit of the warehouse along the planned path.

6. The automatic pallet loading system according to claim 5, characterized in that, The process of the laser-guided stacking forward automatic guide vehicle (1) in S5 transporting two full pallets of goods to the ground buffer area and completing manual / automatic packing includes: the laser-guided stacking forward automatic guide vehicle (1) picks up two full pallets of goods at the exit and runs along the laser navigation path to the ground buffer area for unloading. The ground buffer area is set with eighteen storage positions, and the distance between the storage positions is 1000mm. After the manual packing is completed in the ground buffer area, the manual confirms the completion of packing through the mobile terminal, and the confirmation signal is uploaded to the warehouse management system.

7. The automatic pallet loading system according to claim 6, characterized in that, The process of switching from natural navigation and laser positioning navigation to laser-guided stacking forward-moving automatic guide vehicle (1) in S6 after entering the truck compartment includes: After the laser-guided stacking forward-moving automatic guide vehicle (1) enters the truck compartment, the laser scanner (101) switches to natural navigation mode, scans the point cloud of the compartment wall in real time to build a local map, calculates the real-time position in the compartment through inter-frame point cloud matching and pose map optimization, loads goods row by row according to the dynamically planned loading path, loads one row and two stacks each time, until the whole vehicle is loaded, the laser ranging and positioning component starts laser navigation, and verifies the natural navigation data.

8. The automatic pallet loading system according to claim 7, characterized in that, The system also includes a safety laser graded protection mechanism. During the operation and loading of the laser-guided stacking forward automatic guided vehicle (1), the safety lasers configured under the front of the vehicle, forks and gantry scan the surrounding environment in real time, dividing the emergency stop zone, buffer zone and safe zone. When an obstacle enters the emergency stop zone, it stops immediately, decelerates when entering the buffer zone, and further decelerates when entering the safe zone.

9. The automatic pallet loading system according to claim 8, characterized in that, The system also includes an automatic charging control strategy. When the battery power of the laser-guided stacking forward automatic guide vehicle (1) is less than 30%, it will directly navigate to the charging pile to charge when there is no task, and will go to the charging pile after completing the current task when it is performing a task. It will return to the rest position after charging until the battery power is not less than 90%.

10. A loading device for an automated pallet loading system, characterized in that, The system is applied to an automated pallet loading system according to any one of claims 1-9. The loading equipment is a laser-guided stacking forward automated guided vehicle (1), which includes a laser scanner (101), a safety laser radar (102), a fork mechanism (103), an on-board controller (104), and a wireless communication module (105).

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