Automatic stereoscopic warehouse control method for electric forklift reduction gearbox assembly line

Abstract

The invention discloses a vertical warehouse automatic control method for an electric forklift reduction gearbox assembly line, and the method comprises the steps: carrying out the material shortage calling and material supplementation of a vertical warehouse: triggering a material shortage alarm and prompting material supplementation when the number of any material in the vertical warehouse is smaller than a threshold value, and manually inputting a material name once every time the material supplementation is carried out; dispatching and outputting the materials of the vertical warehouse: when the materials are warehoused, storing the warehouse-in trays according to a first-in first-out mode by a four-way shuttle vehicle and an elevator; when the materials are delivered out of the warehouse, the trays are ferried to a to-be-discharged area by the four-way shuttle vehicle and the elevator according to a first-in first-out mode; and when the material of the tray at the connection position is used up or the required quantity of the discharged material is used up, the tray at the connection position is moved to an idle position by the four-way shuttle vehicle, and then the tray at the to-be-discharged area is moved to the connection position. According to the automatic stereoscopic warehouse control method for the electric forklift reduction gearbox assembly line, the vertical space is fully utilized, the area of a cache region is reduced, and the storage amount of unit area is increased; materials can be guided out in a full-automatic mode, and unmanned dispatching management can be carried out.

Description

Technical Field

[0001] This invention relates to the field of automated storage and retrieval systems (AS / RS), and more specifically, to an automated control method for AS / RS used in electric forklift gearbox assembly lines. Background Technology

[0002] Currently, electric gearboxes are stored flat on the ground. This method has the following drawbacks: 1. Because of the flat ground, vertical space cannot be utilized, resulting in gearboxes occupying a significant area of ​​the workshop. 2. The large storage area prevents gearboxes stored earlier from being retrieved in a timely manner, hindering the first-in, first-out (FIFO) transfer to the next process. 3. The large flat ground area makes dust control difficult, affecting product cleanliness. 4. Ground storage cannot be adjacent to the next process, leading to long material transfer distances and delays. 5. With multiple product types (three types of gearbox bodies A1 / A2 / A3, and corresponding three types of gearbox covers B1 / B2 / B3), separating and transferring materials from the buffer area to the next process is time-consuming and labor-intensive. 6. Material scheduling requires manual intervention.

[0003] Therefore, there is an urgent need for an automated warehouse control method for electric forklift gearbox assembly lines. Summary of the Invention

[0004] The purpose of this invention is to provide an automated control method for an electric forklift gearbox assembly line in an automated warehouse, in order to solve the problems in the prior art.

[0005] This invention provides an automated warehouse control method for an electric forklift gearbox assembly line, comprising:

[0006] Low Material Alarm and Replenishment in Automated Warehouse: When the quantity of any material in the automated warehouse is less than the preset replenishment threshold, a low material alarm is triggered and a replenishment prompt is given. During the replenishment process, the name of the material is manually entered once for each replenishment until the quantity of the missing material meets the requirements, at which point the low material alarm is cleared.

[0007] Automated Warehouse Material Dispatch Output: When materials enter the warehouse, the four-way shuttle and elevator of the automated warehouse store the incoming pallets in the available positions of each aisle in the warehouse according to the first-in-first-out (FIFO) method. When materials leave the warehouse, the automated warehouse triggers the four-way shuttle and elevator according to the assembly material sequence to transfer the pallets to the waiting area in the FIFO method. When the materials on the receiving pallets are used up or the required quantity of the discharged materials is used up, the four-way shuttle first moves the pallets on the receiving pallets to the available positions in the warehouse, and then moves the pallets in the waiting area to the receiving pallets in sequence.

[0008] The automated storage and retrieval system (AS / RS) control method for electric forklift gearbox assembly lines, as described above, preferably includes boxes and lids as the types of materials in the AS / RS. The box types include box A1, box A2, and box A3, and the lid types include lid B1, lid B2, and lid B3. Each pallet can hold six boxes or lids of the same type. The AS / RS has 200 storage locations, each numbered Kn, where n = 1, 2, ..., 200.

[0009] The automated warehouse control method for an electric forklift gearbox assembly line, as described above, preferably includes a material shortage alarm and replenishment mechanism: when the quantity of any material in the warehouse is less than a preset replenishment threshold, a material shortage alarm is triggered, and a replenishment prompt is given. During the replenishment process, the name of the material is manually entered each time it is replenished, until the quantity of the missing material meets the requirements, at which point the material shortage alarm is cleared. This includes:

[0010] When the quantity of any type of box or lid material in the automated storage and retrieval system (AS / RS) is less than the preset replenishment threshold N, a material shortage alarm will be automatically triggered. The screen will display the name and type of the missing material and prompt the user to replenish the material according to the alarm value of 4N-5N. The user must manually enter the name of the material each time it is replenished and the system will automatically count N+1 until the quantity of missing material reaches the 4N-5N range. At this point, the AS / RS will automatically clear the material shortage alarm.

[0011] The automated warehouse control method for an electric forklift gearbox assembly line, as described above, preferably includes the following: When the quantity of any material in the warehouse falls below a preset replenishment threshold, a shortage alarm is triggered, prompting for replenishment. During replenishment, the material name is manually entered each time replenishment is performed until the required quantity of the missing material is met, at which point the shortage alarm is cleared. The method also includes:

[0012] During the replenishment process, material characteristics are identified before a full pallet enters the storage location, and compared with the manually entered material name. If the comparison matches, the material automatically enters the automated storage and retrieval system. If the comparison does not match, a material entry error is triggered, and the process exits for manual handling before proceeding to the next replenishment process.

[0013] The automated storage and retrieval system (AS / RS) control method for an electric forklift gearbox assembly line, as described above, preferably includes the following material scheduling output: When materials enter the warehouse, the four-way shuttle and elevator of the AS / RS store the pallets in the empty positions of each aisle in the AS / RS according to a first-in-first-out (FIFO) method; when materials leave the warehouse, the AS / RS triggers the four-way shuttle and elevator to transfer the pallets to the unloading area according to the assembly material sequence; when the materials on the receiving pallets are used up or the required quantity of unloaded materials is exhausted, the four-way shuttle first moves the pallets from the receiving pallets to an empty position in the AS / RS, and then sequentially moves the pallets from the unloading area to the receiving pallets, including:

[0014] When materials are received, the four-way shuttle and elevator of the automated storage and retrieval system automatically start to store the receiving pallets in the available positions of each aisle in the automated storage and retrieval system in a first-in-first-out manner. The system automatically records the pallet information of the current storage location Kn, which includes: the name of the material on the pallet, the quantity stored, and the storage time information.

[0015] When materials are dispatched, when the automated storage and retrieval system (AS / RS) receives a material call from the assembly line, where the required quantity of materials to be dispatched is L, the AS / RS plans in advance according to the assembly material sequence and triggers the four-way shuttle and the hoist to transfer the pallet to the waiting area in a first-in-first-out manner. The waiting area includes a box body waiting area M1 and a box cover waiting area M2. At this time, the waiting area M1 and the box cover waiting area M2 need to record the pallet information of the waiting area, which includes the name of the material on the pallet, the storage quantity, and the entry time information.

[0016] When the quantity P of materials on the receiving pallet is used up or the quantity L of materials required for the output product is used up, the robot sends a message to the automated warehouse to trigger the four-way shuttle to move the pallet from the receiving pallet to an empty position Kn in the automated warehouse, where n=1, 2....200. The system automatically records the pallet information of the current storage position Kn, which includes the name of the materials that can be stored on the pallet, the storage quantity, and the entry time information.

[0017] The four-way shuttle moves the pallets from the container unloading position M1 and the container cover unloading position M2 to the container docking position M11 and the container cover docking position M22 in sequence, and records the pallet information, including the name of the material on the pallet, the quantity stored, and the time of entry into the warehouse. At the same time, the pallet information is transmitted to the robot.

[0018] Each time the robot grabs a box or lid, the robot automatically decrements the corresponding material count by one within the system.

[0019] The automated warehouse control method for electric forklift gearbox assembly lines, as described above, preferably includes the following: Each time the robot grabs a box or lid, the robot automatically performs a decrement operation on the corresponding material in the system, including:

[0020] If the required quantity L of the output material is a multiple of 6, then when the required quantity L has not decreased to 0, and the quantity P of the material on the pallet at the connection point has decreased to 0, the next cycle for the same type of part begins. When the required quantity L decreases to 0, and the quantity P of the material on the pallet at the connection point decreases to 0, production of another material begins, the system triggers a changeover reminder, and the next type of material is output according to the above method. Simultaneously, the storage quantity on the pallet returning from the connection point to the automated storage and retrieval system is bound to that pallet, and when the pallet returns to the automated storage and retrieval system location Kn (n=1, 2...200), the pallet information is communicated to the automated storage and retrieval system and recorded.

[0021] If the required quantity L of the output material is not an integer multiple of 6, then when the required quantity L has not decreased to 0 and the quantity P of the material on the receiving pallet has decreased to 0, the next cycle for the same type of part begins. When the required quantity L decreases to 0 and the quantity P of the material on the receiving pallet has not decreased to 0, production of another material begins, and the system triggers a changeover reminder, proceeding to the output of the next material in the same manner. Simultaneously, the material name, remaining storage quantity, and storage time on the pallet returning from the receiving pallet to the automated storage unit are reassigned and bound to that pallet. When the pallet returns to the automated storage unit location Kn (n=1, 2...200), this pallet information is communicated to the automated storage system and recorded. Subsequent output materials that match the material on that pallet will be consumed first.

[0022] The automated warehouse control method for an electric forklift gearbox assembly line, as described above, preferably further includes:

[0023] After all materials are entered, they must be compared with the characteristics of the materials when they enter the automated storage and retrieval system. If the comparison is inconsistent, the materials will be removed from the automated storage and manually judged and re-entered.

[0024] If the robot is picking up materials at the docking station, the four-way shuttle is not allowed to enter the docking station. If the four-way shuttle has already entered the docking station, the robot is not allowed to execute the picking up procedure.

[0025] After all materials leave the warehouse, the robot must re-identify the material characteristics before picking them up and compare them with the incoming material information. If the comparison is inconsistent, picking up the material is prohibited, and the problematic pallet is moved to the loading end or unloading end by a four-way shuttle car. Manual intervention is required to handle the issue and re-enter the information.

[0026] The automated warehouse control method for an electric forklift gearbox assembly line, as described above, preferably further includes:

[0027] Nighttime material handling in automated storage and retrieval systems: Before the end of the workday, the production material schedule for the next day is imported into the automated storage and retrieval system. At night, the materials are sorted into pallets in the automated storage and retrieval system according to the production schedule. Each aisle of the automated storage and retrieval system can accommodate three pallets. The materials are sorted according to the entry and exit order of the innermost and last exiting materials, and the materials are placed outside the aisle according to the time of entry. The materials that enter the warehouse first are placed outside the aisle, and then placed in the next aisle in turn.

[0028] This invention provides an automated vertical warehouse (AS / RS) control method for electric forklift gearbox assembly lines. It fully utilizes vertical space, reduces buffer area, and increases storage capacity per unit area. The floor space is reduced from 250㎡ to 120㎡, and the storage capacity per unit area is increased from 3 sets / m² to 6 sets / m², where 1 set = 1 housing + 1 cover. The AS / RS is multi-layered with interconnected passages between layers, enabling first-in-first-out (FIFO) material handling and effectively reducing material removal time, allowing for timely material transfer to subsequent processes. Material removal is fully automated according to control logic, requiring no manual intervention and enabling unmanned scheduling and management. Materials are concentrated in a multi-layered vertical space, and dustproof PVC panels around the AS / RS effectively prevent dust from affecting the parts inside, ensuring the cleanliness of work-in-process. Attached Figure Description

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below with reference to the accompanying drawings, wherein:

[0030] Figure 1 A flowchart illustrating an embodiment of the automated warehouse control method for an electric forklift gearbox assembly line provided by the present invention;

[0031] Figure 2 This is a schematic diagram of the vertical warehouse structure of the electric forklift gearbox assembly line provided by the present invention. Detailed Implementation

[0032] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0033] The terms “first,” “second,” and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Terms such as “including” or “contains” mean that the element preceding the term encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as “above” and “below” are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0034] In this disclosure, when a specific component is described as being located between a first component and a second component, an intermediary component may or may not be present between the specific component and the first or second component. When a specific component is described as connecting to other components, the specific component may be directly connected to the other components without having an intermediary component, or it may not be directly connected to the other components but may have an intermediary component.

[0035] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0036] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0037] like Figure 1 As shown, the automated warehouse control method for electric forklift gearbox assembly lines provided in this embodiment includes the following steps in actual implementation:

[0038] Step S1, Material Shortage Call and Replenishment in Automated Warehouse: When the quantity of any material in the automated warehouse is less than the preset replenishment threshold, a material shortage alarm is triggered and a replenishment prompt is given. During the replenishment process, the name of the material is manually entered each time it is replenished until the quantity of the missing material meets the requirements, at which point the material shortage alarm is cleared.

[0039] Among them, such as Figure 2As shown, the automated storage and retrieval system (AS / RS) includes: a hoist, a four-way shuttle, an AS / RS frame, connection points, a waiting area for material discharge, and a replenishment area. The materials in the AS / RS include boxes and box lids. The box models include box A1, box A2, and box A3, and the box lid models include lid B1, lid B2, and lid B3. Each pallet can hold six boxes or lids of the same model. The AS / RS has 200 storage locations, each numbered Kn, where n = 1, 2, ..., 200. The AS / RS is multi-level, with interconnecting passages between levels, enabling first-in, first-out (FIFO) material handling and effectively reducing the time spent on material discharge, allowing for timely material transfer to subsequent processes. Furthermore, the materials are concentrated in a multi-level, three-dimensional space, and the dustproof PVC panels surrounding the AS / RS effectively prevent dust from affecting the parts inside, ensuring the cleanliness of work-in-process.

[0040] Specifically, when the quantity of any type of box or lid (such as box A1, box A2, box A3, lid B1, lid B2, lid B3) in the automated storage and retrieval system (AS / RS) is less than the preset replenishment threshold N, a material shortage alarm will be automatically triggered. The screen will display the name and type of the missing material (A1, A2, A3, B1, B2, B3) and prompt the user to replenish the material according to the alarm value of 4N-5N. The name of the material will be manually entered each time it is replenished, and the system will automatically count N+1 until the quantity of missing material reaches the 4N-5N range. At this point, the AS / RS will automatically clear the material shortage alarm.

[0041] Furthermore, during the replenishment process, material characteristics are identified before a full pallet enters the storage location, and compared with the manually entered material name. If the comparison matches, the material automatically enters the automated storage and retrieval system. If the comparison does not match, a material entry error is triggered, and the process exits for manual processing, proceeding to the next replenishment process.

[0042] Step S2, Automated Warehouse Material Scheduling Output: When materials enter the warehouse, the four-way shuttle and elevator of the automated warehouse store the incoming pallets in the available positions of each aisle in the warehouse according to the first-in-first-out (FIFO) method; when materials leave the warehouse, the automated warehouse triggers the four-way shuttle and elevator to transfer the pallets to the waiting area according to the first-in-first-out (FIFO) method based on the assembly material sequence; when the materials on the connecting position pallets are used up or the required quantity of the discharged products is used up, the four-way shuttle first moves the pallets from the connecting position to the available positions in the warehouse, and then moves the pallets from the waiting area to the connecting position in sequence.

[0043] In one embodiment of the automated warehouse control method for an electric forklift gearbox assembly line of the present invention, step S2 may specifically include:

[0044] Step S21: When materials are received, the four-way shuttle and elevator of the automated storage and retrieval system automatically start to store the receiving pallets in the available positions of each aisle in the automated storage and retrieval system in a first-in-first-out manner. The system automatically records the pallet information of the current storage location Kn, which includes: the name of the material on the pallet, the storage quantity, and the storage time information.

[0045] Step S22: When materials are dispatched, if the automated storage and retrieval system (AS / RS) receives a material call from the assembly line, and the required quantity of the dispatched materials (A1\A2\A3\B1\B2\B3) is L, the AS / RS will plan in advance according to the assembly material sequence and trigger the four-way shuttle and the hoist to transfer the pallets to the waiting area in a first-in-first-out manner. The waiting area includes the box body waiting area M1 and the box cover waiting area M2. At this time, the waiting area M1 and the box cover waiting area M2 need to record the pallet information of the waiting area, which includes the material name on the pallet, the storage quantity, and the warehousing time information.

[0046] Step S23: When the quantity P of materials on the connecting pallet is used up or the required quantity L of the discharged materials (A1\A2\A3\B1\B2\B3) is used up, the robot sends a message to the automated warehouse to trigger the four-way shuttle to move the pallet from the connecting pallet to the empty position Kn of the automated warehouse, n=1, 2....200. The system automatically records the pallet information of the current storage position Kn, which includes the name of the materials that can be stored on the pallet, the storage quantity, and the storage time information.

[0047] The docking position refers to the location where the material is connected between the supply warehouse and the material loading robot of the cleaning machine.

[0048] Step S24: The four-way shuttle moves the pallets from the box unloading position M1 and the box cover unloading position M2 (i.e., the waiting area) to the box connection position M11 and the box cover connection position M22 (i.e., the connection position) in sequence, and records the pallet information, which includes the name of the material on the pallet, the storage quantity, and the storage time information. At the same time, the pallet information is transmitted to the robot.

[0049] Step S25: Each time the robot grabs a box or box lid, the robot automatically decrements the corresponding material in the system.

[0050] Specifically, if the required quantity L of the output material is an integer multiple of 6, then when the required quantity L has not decreased to 0 and the quantity P of the material on the pallet at the connection point has decreased to 0, the next cycle of the same type of part will begin; when the required quantity L of the output material decreases to 0 and the quantity P of the material on the pallet at the connection point decreases to 0, the production of another material will begin, the system will trigger a changeover reminder, and the next type of material will be output in the same manner as described above; at the same time, the storage quantity on the pallet returning from the connection point to the automated warehouse will be bound to the pallet, and when the pallet returns to the automated warehouse location Kn (n=1, 2....200), the pallet information will be informed to the automated warehouse system and recorded.

[0051] If the required quantity L of the output material is not an integer multiple of 6, then when the required quantity L has not decreased to 0 and the quantity P of the material on the receiving pallet has decreased to 0, the next cycle for the same type of part begins. When the required quantity L decreases to 0 and the quantity P of the material on the receiving pallet has not decreased to 0, production of another material begins, and the system triggers a changeover reminder, proceeding to the output of the next material in the same manner. Simultaneously, the material name, remaining storage quantity, and storage time on the pallet returning from the receiving pallet to the automated storage unit are reassigned and bound to that pallet. When the pallet returns to the automated storage unit location Kn (n=1, 2...200), this pallet information is communicated to the automated storage system and recorded. Subsequent output materials that match the material on that pallet will be consumed first.

[0052] Furthermore, in one embodiment of the present invention, the automated warehouse control method for an electric forklift gearbox assembly line further includes:

[0053] After all materials are entered, they must be compared with the characteristics of the materials when they enter the automated storage and retrieval system. If the comparison is inconsistent, the materials will be removed from the automated storage and manually judged and re-entered.

[0054] If the robot is picking up materials at the docking station (i.e., when the robot is executing the picking up procedure), the four-way shuttle is not allowed to enter the docking station. If the four-way shuttle has already entered the docking station, the robot is not allowed to execute the picking up procedure.

[0055] After all materials leave the warehouse, the robot must re-identify the material characteristics before picking them up and compare them with the incoming material information. If the comparison is inconsistent, picking up the material is prohibited, and the problematic pallet is moved to the loading end or unloading end by a four-way shuttle car. Manual intervention is required to handle the issue and re-enter the information.

[0056] By taking the above three measures, the safety of the storage facility can be guaranteed to the greatest extent.

[0057] Furthermore, in one embodiment of the present invention, the automated warehouse control method for an electric forklift gearbox assembly line further includes:

[0058] Nighttime material handling in automated storage and retrieval systems (AS / RS): Before the end of the workday, the production material schedule for the next day is imported into the AS / RS. At night, the materials (A1, A2, A3, B1, B2, B3) are sorted into pallets in the AS / RS according to the production schedule. Each aisle of the AS / RS can accommodate three pallets. The materials (A1, A2, A3, B1, B2, B3) are arranged according to their entry and exit order, with the first ones entering the warehouse placed outside the aisle and then moved in sequentially, continuing into the next aisle.

[0059] This invention, by adding nighttime material discharge to the vertical storage unit, ensures that the assembly line calls materials from the vertical storage unit during daytime operations, shortening the material unloading time of the vertical storage unit according to the first-in-first-out method, and prioritizing the continuous operation of the vertical storage unit → cleaning machine → assembly according to the predetermined rhythm.

[0060] The automated storage and retrieval system (AS / RS) control method for electric forklift gearbox assembly lines provided in this invention fully utilizes vertical space, reduces buffer area, and increases storage capacity per unit area. The floor area is reduced from 250㎡ to 120㎡, and the storage capacity per unit area is increased from 3 sets / m² to 6 sets / m², where 1 set = 1 housing + 1 cover. The AS / RS is multi-layered with interconnected channels between each layer, enabling first-in-first-out (FIFO) material handling and effectively reducing material unloading time, allowing for timely material transfer to subsequent processes. Material unloading is fully automated according to control logic, requiring no manual intervention and enabling unmanned scheduling and management. Materials are concentrated in a multi-layered vertical space, and the dustproof PVC panels surrounding the AS / RS effectively prevent dust from affecting the parts inside, ensuring the cleanliness of work-in-process.

[0061] The embodiments of this disclosure have now been described in detail. To avoid obscuring the concept of this disclosure, some details known in the art have not been described. Those skilled in the art can fully understand how to implement the technical solutions disclosed herein based on the above description.

[0062] While specific embodiments of this disclosure have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. An automated warehouse control method for an electric forklift gearbox assembly line, characterized in that, include: Low Material Alarm and Replenishment in Automated Warehouse: When the quantity of any material in the automated warehouse is less than the preset replenishment threshold, a low material alarm is triggered and a replenishment prompt is given. During the replenishment process, the name of the material is manually entered once for each replenishment until the quantity of the missing material meets the requirements, at which point the low material alarm is cleared. Automated Warehouse Material Dispatch Output: When materials enter the warehouse, the four-way shuttle and elevator of the automated warehouse store the incoming pallets in the available positions of each aisle in the warehouse according to the first-in-first-out (FIFO) method. When materials leave the warehouse, the automated warehouse triggers the four-way shuttle and elevator according to the assembly material sequence to transfer the pallets to the waiting area in the FIFO method. When the materials on the receiving pallets are used up or the required quantity of the discharged materials is used up, the four-way shuttle first moves the pallets on the receiving pallets to the available positions in the warehouse, and then moves the pallets in the waiting area to the receiving pallets in sequence.

2. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 1, characterized in that, The materials in the automated storage and retrieval system include boxes and lids. The box models include box A1, box A2, and box A3, and the lid models include lid B1, lid B2, and lid B3. Each pallet can hold 6 boxes or lids of the same model. The automated storage and retrieval system has a total of 200 storage locations, each numbered Kn, where n = 1, 2, ..., 200.

3. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 2, characterized in that, The automated storage and retrieval system (AS / RS) material shortage alarm and replenishment mechanism: When the quantity of any material in the AS / RS falls below a preset replenishment threshold, a material shortage alarm is triggered, prompting for replenishment. During the replenishment process, the name of the material is manually entered each time replenishment is performed until the quantity of the missing material meets the requirements, at which point the material shortage alarm is cleared. This includes: When the quantity of any type of box or lid material in the automated storage and retrieval system (AS / RS) is less than the preset replenishment threshold N, a material shortage alarm will be automatically triggered. The screen will display the name and type of the missing material and prompt the user to replenish the material according to the alarm value of 4N-5N. The user must manually enter the name of the material each time it is replenished and the system will automatically count N+1 until the quantity of missing material reaches the 4N-5N range. At this point, the AS / RS will automatically clear the material shortage alarm.

4. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 3, characterized in that, The automated storage and retrieval system (AS / RS) material shortage alarm and replenishment mechanism: When the quantity of any material in the AS / RS falls below a preset replenishment threshold, a material shortage alarm is triggered, prompting for replenishment. During the replenishment process, the name of the material is manually entered each time it is replenished, until the quantity of the missing material meets the requirements, at which point the material shortage alarm is cleared. The system also includes: During the replenishment process, material characteristics are identified before a full pallet enters the storage location, and compared with the manually entered material name. If the comparison matches, the material automatically enters the automated storage and retrieval system. If the comparison does not match, a material entry error is triggered, and the process exits for manual handling before proceeding to the next replenishment process.

5. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 1, characterized in that, The automated storage and retrieval system (AS / RS) material dispatch output is as follows: When materials enter the AS / RS, the four-way shuttle and elevator store the pallets in the available positions of various aisles according to the first-in, first-out (FIFO) principle. When materials leave the AS / RS, the four-way shuttle and elevator, based on the assembly material sequence, transfer the pallets to the unloading area according to the FIFO principle. When the materials on the receiving pallets are used up or the required quantity of materials for the discharge product is exhausted, the four-way shuttle first moves the pallets from the receiving pallets to an available position in the AS / RS, and then sequentially moves the pallets from the unloading area to the receiving pallets, including: When materials are received, the four-way shuttle and elevator of the automated storage and retrieval system automatically start to store the receiving pallets in the available positions of each aisle in the automated storage and retrieval system in a first-in-first-out manner. The system automatically records the pallet information of the current storage location Kn, which includes: the name of the material on the pallet, the quantity stored, and the storage time information. When materials are dispatched, when the automated storage and retrieval system (AS / RS) receives a material call from the assembly line, where the required quantity of materials to be dispatched is L, the AS / RS plans in advance according to the assembly material sequence and triggers the four-way shuttle and the hoist to transfer the pallet to the waiting area in a first-in-first-out manner. The waiting area includes a box body waiting area M1 and a box cover waiting area M2. At this time, the waiting area M1 and the box cover waiting area M2 need to record the pallet information of the waiting area, which includes the name of the material on the pallet, the storage quantity, and the entry time information. When the quantity P of materials on the receiving pallet is used up or the quantity L of materials required for the output product is used up, the robot sends a message to the automated warehouse to trigger the four-way shuttle to move the pallet from the receiving pallet to an empty position Kn in the automated warehouse, where n=1, 2....

200. The system automatically records the pallet information of the current storage position Kn, which includes the name of the materials that can be stored on the pallet, the storage quantity, and the entry time information. The four-way shuttle moves the pallets from the container unloading position M1 and the container cover unloading position M2 to the container docking position M11 and the container cover docking position M22 in sequence, and records the pallet information, including the name of the material on the pallet, the quantity stored, and the time of entry into the warehouse. At the same time, the pallet information is transmitted to the robot. Each time the robot grabs a box or lid, the robot automatically decrements the corresponding material count by one within the system.

6. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 5, characterized in that, Each time the robot grabs a box or lid, the robot automatically decrements the corresponding material count in the system, including: If the required quantity L of the output material is a multiple of 6, then when the required quantity L has not decreased to 0, and the quantity P of the material on the pallet at the connection point has decreased to 0, the next cycle for the same type of part begins. When the required quantity L decreases to 0, and the quantity P of the material on the pallet at the connection point decreases to 0, production of another material begins, the system triggers a changeover reminder, and the next type of material is output according to the above method. Simultaneously, the storage quantity on the pallet returning from the connection point to the automated storage and retrieval system is bound to that pallet, and when the pallet returns to the automated storage and retrieval system location Kn (n=1, 2...200), the pallet information is communicated to the automated storage and retrieval system and recorded. If the required quantity L of the output material is not an integer multiple of 6, then when the required quantity L has not decreased to 0 and the quantity P of the material on the receiving pallet has decreased to 0, the next cycle for the same type of part begins. When the required quantity L decreases to 0 and the quantity P of the material on the receiving pallet has not decreased to 0, production of another material begins, and the system triggers a changeover reminder, proceeding to the output of the next material in the same manner. Simultaneously, the material name, remaining storage quantity, and storage time on the pallet returning from the receiving pallet to the automated storage unit are reassigned and bound to that pallet. When the pallet returns to the automated storage unit location Kn (n=1, 2...200), this pallet information is communicated to the automated storage system and recorded. Subsequent output materials that match the material on that pallet will be consumed first.

7. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 1, characterized in that, The automated warehouse control method for electric forklift gearbox assembly lines also includes: After all materials are entered, they must be compared with the characteristics of the materials when they enter the automated storage and retrieval system. If the comparison is inconsistent, the materials will be removed from the automated storage and manually judged and re-entered. If the robot is picking up materials at the docking station, the four-way shuttle is not allowed to enter the docking station. If the four-way shuttle has already entered the docking station, the robot is not allowed to execute the picking up procedure. After all materials leave the warehouse, the robot must re-identify the material characteristics before picking them up and compare them with the incoming material information. If the comparison is inconsistent, picking up the material is prohibited, and the problematic pallet is moved to the loading end or unloading end by a four-way shuttle car. Manual intervention is required to handle the issue and re-enter the information.

8. The automated warehouse control method for an electric forklift gearbox assembly line according to claim 1, characterized in that, The automated warehouse control method for electric forklift gearbox assembly lines also includes: Nighttime material handling in automated storage and retrieval systems: Before the end of the workday, the production material schedule for the next day is imported into the automated storage and retrieval system. At night, the materials are sorted into pallets in the automated storage and retrieval system according to the production schedule. Each aisle of the automated storage and retrieval system can accommodate three pallets. The materials are sorted according to the entry and exit order of the innermost and last exiting materials, and the materials are placed outside the aisle according to the time of entry. The materials that enter the warehouse first are placed outside the aisle, and then placed in the next aisle in turn.

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