Electric wire storage intelligent management method and system based on RFID and weighing induction

Abstract

The invention discloses a wire storage intelligent management method and system based on RFID and weighing induction, and relates to the technical field of intelligent storage. The system comprises a weight sensing tray, a data processing center, an RFID label printer and a handheld terminal. The invention creatively provides a closed-loop system architecture of weight sensing, center calculation, dynamic binding and real-time query aiming at the long-standing pain points that management depends on manpower, the management work efficiency is low and the RFID technology application cost is high in the wire and cable storage industry. According to the system, data is automatically collected through a weight sensing tray, a data center calculates inventory and dynamically generates a binding instruction, and an RFID printer is driven to print a label attached to the tray; during inventory checking, the latest inventory can be inquired in real time based on the IP address by reading the label through the handheld terminal. According to the invention, the RFID tag is innovated from the traditional accurate customization which can be realized by binding to each cargo and establishing an independent storage location to the dynamic binding of the tray, the application and management cost of the RFID is obviously reduced in a one-tray one-sign mode on the premise of not greatly increasing the hardware investment cost, the flexible decoupling of the cargo and the storage location is realized, and the flexibility of the system is improved. A set of economic, efficient and intelligent warehousing solution with full-automatic inventory, high-precision data and real-time information is provided for the wire and cable industry.

Description

A Smart Management Method and System for Wire Warehouse Based on RFID and Weighing Sensing Technical Field

[0001] This invention relates to the fields of intelligent warehousing and Internet of Things (IoT) technology, specifically to an intelligent management method and system for inbound and outbound operations and inventory based on a combination of RFID (Radio Frequency Identification) technology and weighing sensing technology, applicable to the wire and cable industry. Background Technology

[0002] As a basic material, electrical wire has long faced unique challenges in its warehousing management. The product is mostly in the form of heavy cylindrical coils, and traditional management relies on manual ledgers and Excel records, resulting in information delays, inventory difficulties, low efficiency in inbound and outbound operations, and high dependence on employee experience. Barcode technology is unsuitable due to the irregular surface of the wire coils and their susceptibility to soiling. While RFID technology offers advantages such as contactless identification and batch reading, both traditional tagging and RFID technologies require binding tags to goods. RFID technology, in particular, requires establishing separate storage locations for precise goods positioning. Furthermore, the cost of a single RFID tag ranges from 0.2 to 0.7 yuan or even higher. If tags are bound to each wire coil, the inherent cost of a single RFID tag becomes negligible in a warehousing scenario due to the large number of tags used, leading to high overall tag costs. Additionally, the frequent movement of wire coils complicates the management of the tag-to-storage-location relationship. Equipping each storage location (pallet) with an RFID reader for dynamic binding would result in excessively high hardware investment costs.

[0003] Therefore, there is a need for an intelligent warehouse management solution that can leverage the advantages of RFID technology, significantly reduce long-term operating costs, and adapt to the characteristics of the wire industry. Summary of the Invention

[0004] The technical problem to be solved by this invention is to overcome the shortcomings of existing wire storage management methods, such as low level of intelligence, low efficiency of traditional management work, high cost and poor flexibility of existing RFID technology in this industry.

[0005] To solve the above problems, the present invention uses the following solution:

[0006] In a first aspect, the present invention provides an intelligent management system for wire storage based on RFID and weighing sensing, characterized in that it includes:

[0007] Weight sensing tray: used to collect the total weight of the wires it carries in real time, and upload the weight data and its own network address information;

[0008] Data processing center: Communicates with the weight-sensing tray, receives the weight data and network address information, determines the weight change value (ΔM) and its direction of change by comparing continuously received weight data, calculates the corresponding change in inventory quantity based on the weight change value (ΔM) and the preset standard weight of a single roll, and updates the inventory record; also generates RFID binding data instructions containing wire attribute information and the associated weight-sensing tray network address.

[0009] RFID tag printer: It is connected to the data processing center to receive the RFID binding data instruction and write the wire attribute information and the associated weight sensing tray network address into a blank RFID tag.

[0010] Handheld terminal: Used to read the information stored in the RFID tag and, based on the read weight-sensing tray network address, connect to the data processing center to query the real-time inventory data corresponding to the network address.

[0011] Secondly, the present invention provides an intelligent management method for wire storage based on RFID and weighing sensing, applied to the system described in the first aspect, characterized by comprising the following steps:

[0012] S1: The weight-sensing tray uploads the total weight of the carrying wires and its own network address information to the data processing center.

[0013] S2: The data processing center determines the weight change value (ΔM) and its direction of change based on the continuously received weight data, calculates the corresponding change in inventory quantity in conjunction with the preset standard weight of a single roll, and updates the inventory record.

[0014] S3: The data processing center generates an RFID binding data instruction containing wire attribute information and the associated weight sensing tray network address, and drives the RFID tag printer to write the information into a blank RFID tag.

[0015] S4: Read the RFID tag affixed to the pallet using a handheld terminal, and query the real-time inventory data from the data processing center based on the read pallet network address.

[0016] The beneficial effects of this invention are as follows:

[0017] Significantly reduced costs: Weight-sensing pallets only require basic weighing and communication functions, eliminating the need for expensive RFID reader / writer modules; RFID tags are printed only when goods are first associated with the pallet, avoiding the pre-writing and waste of numerous tags. The total hardware investment and long-term operating costs are far lower than traditional solutions.

[0018] Highly flexible management: By dynamically establishing and maintaining a soft binding relationship between "wire attributes and pallet network addresses" through the data processing center, the decoupling of goods and physical storage locations is achieved. Wire reels can be flexibly transferred between different pallets, and the system automatically tracks their location via IP address, effectively solving the traditional RFID tag management problems caused by the high mobility of products.

[0019] Accurate and Real-Time Data: Inventory data is automatically calculated and generated based on high-precision weighing sensors, eliminating errors from manual counting at the source. During inventory checks, the central database is queried in real time via the network address bound to the tags, ensuring that the information obtained is always the latest system data, achieving "real-time consistency between accounts and physical inventory".

[0020] Intelligent management throughout the entire process: It realizes closed-loop management of the entire process from automatic binding of goods entering the warehouse, automatic measurement of goods leaving the warehouse, automatic inventory updates to real-time on-site inventory counting, which greatly reduces the manual intervention links and improves the overall intelligence level and operational efficiency of wire warehouse management. Attached Figure Description

[0021] Figure 1 is a schematic diagram of the system architecture provided in an embodiment of the present invention.

[0022] Figure 2 is a flowchart of the management method provided in an embodiment of the present invention.

[0023] Figure 3 is a timeline diagram of data binding and real-time query provided in an embodiment of the present invention.

[0024] Figure 4 is a schematic diagram of a weight-sensing tray structure provided in an embodiment of the present invention.

[0025] Explanation of reference numerals in the attached figures

[0026] Figure 4: 1 is the fixed limit device, 2 is the movable limit device, and 3 is the distribution position of the weight sensor. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only for explaining this invention and are not intended to limit the scope of protection of this invention.

[0028] Example: Referring to Figures 1 to 4, this example details a complete process for the management of wire warehousing, storage, outbound and inventory.

[0029] I. System Initialization and Parameter Settings

[0030] Several weight-sensing pallets with unique IP addresses (e.g., IP: 192.168.1.101-110) are deployed in the warehouse. Before use, a load calibration is required: ensure the pallet is unloaded, and zero the weight reading using its own zeroing function or via system software commands. This operation aims to eliminate system errors caused by variations in the pallet's structural weight (tare weight), ensuring that the reported weight value directly represents the net weight of the cables it carries.

[0031] Subsequently, the administrator sampled a batch of newly arrived electrical wires (specifications: BV2.5mm², red), randomly measuring three rolls using a precision electronic scale. The measured weights were 3.02kg, 3.05kg, and 3.08kg, respectively. The average weight of 3.05kg was calculated as the "standard weight per roll (Wu)" for this batch of wires and manually entered into the parameter database of the data processing center. Simultaneously, the system needs to set a "minimum sensing threshold." This threshold is used to distinguish between actual changes in cargo weight and inherent hardware conditions of the weighing sensor or minor environmental disturbances. Its value can be determined in the following ways: after system installation, collect pallet weight fluctuation data under no-load or stable load conditions over a period of time, and use its statistical characteristic value (e.g., three standard deviations) as the threshold; or the administrator can directly set and enter it into the system based on experience (e.g., 10% of the standard weight per roll).

[0032] The weight-sensing tray features a limiting design for wire rolls, as shown in Figure 4. Its bearing surface has multiple parallel strip-shaped baffles. The limiting devices on both sides are fixed structures, while at least one limiting device in the middle is an adjustable device that can move along the length of the tray. By adjusting the position of the middle device, storage spaces of different widths can be created, flexibly and stably accommodating the storage of wire rolls of different diameters or quantities. This design physically achieves adaptive adjustment of storage space, fundamentally preventing weighing errors caused by sudden tray movement due to inconsistent wire roll specifications or unstable placement. Furthermore, the tray's weighing module employs a multi-point distributed sensor layout (arranged at the four corners of the tray bottom or specific support points) to uniformly sense weight and eliminate weighing errors that may arise from different wire roll placement positions.

[0033] II. Initial Inventory Receipt and Information Binding Process

[0034] S101: The operator places 50 rolls of the above-mentioned wire, in groups of 10, on 5 calibrated weight sensor trays (assuming IPs are 192.168.1.101 to 105).

[0035] S102: After the weight sensors inside each pallet detect that the weight has stabilized, they report the currently monitored weight data and their own IP address to the data processing center via Wi-Fi network. For example, the pallet with IP address 192.168.1.101 reports a weight of 30.5 kg.

[0036] S103: After the data processing center receives stable weight data from a certain IP address (such as 192.168.1.101) for the first time, it automatically executes the binding logic in combination with the entered product specifications: generating an RFID binding data instruction with the content of {Specifications: BV2.5, Red, Binding Pallet IP: 192.168.1.101, Initial Quantity: 10}.

[0037] S104: The RFID tag printer connected to the data processing center network receives the instruction, drives the printing engine, encodes the above information, and writes it into the chip user storage area of ​​a blank RFID tag.

[0038] S105: The operator affixes the printed RFID tag to a prominent position on the pallet, thus completing the binding of the batch of 10 rolls of wire to the pallet's IP address "192.168.1.101". Repeat steps S103-S105 for the remaining 4 pallets (IP: 192.168.1.102 to 192.168.1.105).

[0039] III. Inbound / Outbound and Automatic Inventory Update Process

[0040] The inventory update logic of the data processing center fully covers the operations of goods deposit, partial withdrawal, and complete retrieval. Its core judgment and execution process is as follows:

[0041] Calculation and preliminary qualitative analysis: By comparing the current stable weight (M1) with the previously recorded stable weight (M2), the weight change ΔM = M1-M2 is calculated.

[0042] Classification and Execution:

[0043] Inbound: If ΔM > 0 and its absolute value exceeds the system's preset minimum sensing threshold, it is determined to be an inbound operation. The system calculates the change in inventory quantity N = ΔM / Wu and adds this quantity to the inventory record for that pallet.

[0044] Outbound (partial and full): If ΔM < 0 and its absolute value exceeds the minimum sensing threshold, it is determined to be an outbound operation. The system will then perform a crucial second-level judgment:

[0045] Determine if the system is unloaded: Check if the current weight M1 differs from the system's preset tare weight of the pallet within the allowable error range.

[0046] Branch processing:

[0047] If the system determines the pallet to be empty, it means that all the goods on the pallet have been removed. The system will then perform a "clear" operation, directly resetting the inventory record corresponding to that pallet to zero.

[0048] If the system determines that the shipment is not empty, it means that this is a partial outbound shipment. The system performs a "calculation" operation, calculates the outbound quantity according to the formula N=|ΔM| / Wu, and subtracts this quantity from the inventory record.

[0049] Ignore fluctuations: If the value of |ΔM| is less than or equal to the system's preset minimum sensing threshold, it is considered an invalid fluctuation, and the system will not update the inventory record. The standard weight Wu per roll is a preset value for the same specification of wire. The system automatically updates the inventory record based on the calculated quantity change.

[0050] The following is a detailed explanation using outbound shipment as an example:

[0051] S201: The material handler takes a portion of the wire rolls from the tray with IP address 192.168.1.102 according to the work order.

[0052] S202: After the goods were picked up, the weight of the pallet was stabilized at 21.35kg and was immediately reported (M1: 21.35kg, IP: 192.168.1.102).

[0053] S203: After receiving the data, the data processing center finds the last reported stable weight of the pallet in the record as 30.5kg, and calculates ΔM = 21.35-30.5=-9.15kg.

[0054] S204: Since ΔM < 0, the system determines that the item is being shipped out. Wu = 3.05 kg is retrieved, and N = 9.15 / 3.05 = 3.0 is calculated. After rounding, 3 rolls are shipped out (in this example, the integer value is used).

[0055] S205: The data processing center automatically updated the pallet inventory record for IP address 192.168.1.102 from 10 volumes to 7 volumes.

[0056] S206: The verification module can compare the calculated result 3 with the planned quantity of the inbound and outbound work orders. If the deviation exceeds the threshold, an alarm will be triggered.

[0057] IV. Real-time Inventory Process

[0058] S301: The warehouse manager enters the warehouse with a handheld terminal, which has a built-in UHF RFID reader / writer module and a wireless network communication module.

[0059] S302: The handheld terminal approaches the tray and reads the information stored in the RFID tag attached to it, successfully obtaining the wire specification information (such as BV2.5, red) and its associated weight-sensing tray network address (such as 192.168.1.102).

[0060] S303: The application within the handheld terminal automatically extracts the above information and sends a structured inventory query request to the data processing center via the wireless network. The core purpose of this request is to inquire: "What is the current inventory quantity of the BV2.5 red wire on the tray with IP address 192.168.1.102?"

[0061] S304: The data processing center receives and parses the query request and immediately performs a retrieval in its real-time inventory database.

[0062] S305: After the retrieval is completed, the data processing center will encapsulate the query results (e.g., the current inventory is 7 volumes) into a data packet and return it to the handheld terminal via the network.

[0063] S306: The handheld terminal receives and parses the returned data packets, and finally displays the results clearly on the screen to the warehouse manager, such as: "Pallet IP: 192.168.1.102, Specification: BV2.5, Red, Current Stock: 7 rolls".

[0064] S307: Warehouse staff can move quickly and repeat this process to read other tags, efficiently completing full or partial inventory counts, and all data is in real-time, eliminating the need for manual counting.

[0065] The above embodiments fully illustrate the system structure, workflow, and technical effects of the present invention.

[0066] This invention provides a practical and cost-effective intelligent warehousing solution for wire management in the wire and cable industry through an innovative soft-binding architecture and centralized computing mode, using a closed-loop system architecture of "weight sensing - centralized computing - dynamic binding - real-time query".

Claims

1. A smart management system for wire storage based on RFID and weighing sensing, characterized in that, include: A weight-sensing tray is used to collect the total weight of the wires it carries in real time and upload the weight data and its own network address information. The data processing center, communicatively connected to the weight-sensing tray, receives the weight data and network address information. By comparing the currently received weight data with the previously received weight data, it determines the weight change value (ΔM) and its direction of change (increase or decrease). Based on the weight change value (ΔM) and a preset standard weight per roll, it calculates the corresponding change in inventory quantity and updates the inventory record. It also generates RFID binding data instructions containing wire attribute information and the associated weight-sensing tray network address. An RFID tag printer, communicatively connected to the data processing center, receives the RFID binding data instructions and writes the wire attribute information and the associated weight-sensing tray network address into blank RFID tags. A handheld terminal is used to read the information stored in the RFID tag and, based on the read weight-sensing tray network address, to query the real-time inventory data corresponding to the network address from the data processing center.

2. The system according to claim 1, characterized in that, The standard weight of a single roll is preset in the data processing center in the following way: sampling and weighing wires from the same batch, and manually entering the measured weight value of a single roll.

3. The system according to claim 1, characterized in that, The wire attribute information written into the RFID tag includes at least: specifications, model, color, and initial quantity.

4. The system according to claim 1, characterized in that, The data processing center is also used to: automatically generate the RFID binding data instruction corresponding to the network address of the pallet when it first receives weight data reported from a weight-sensing pallet, and drive the RFID tag printer to print the tag.

5. The system according to claim 1, characterized in that, The handheld terminal is configured to: automatically extract the pallet network address from the RFID tag after reading it, and send an inventory query request containing the address to the data processing center; receive and display the real-time inventory quantity returned by the data processing center.

6. The system according to claim 1, characterized in that, When the data processing center calculates the change in inventory quantity N based on the weight data difference ΔM and the standard weight of a single roll Wu, the formula used is N=|ΔM| / Wu, and the calculation result is rounded down.

7. The system according to claim 6, characterized in that, The data processing center also includes a verification module, which, after calculating the inventory quantity change value N, compares it with the expected quantity on the planned outbound / inbound document corresponding to the current outbound operation; if the deviation exceeds a preset threshold, an abnormal alarm is generated.

8. The system according to claim 1, characterized in that, The bearing surface of the weight-sensing tray is a limiting device adapted to cylindrical wire coils, and its weighing sensors adopt a multi-point distributed layout.

9. A method for intelligent management of wire storage based on RFID and weighing sensing, applied to the system described in any one of claims 1-8, characterized in that, Includes the following steps: S1: The weight-sensing tray uploads the total weight of the loaded wires and its own network address information to the data processing center; S2: The data processing center determines the weight change value (ΔM) and its direction of change based on the currently received weight data and the previously received weight data, calculates the corresponding change in inventory quantity in conjunction with the preset standard weight per roll, and updates the inventory record; S3: The data processing center generates an RFID binding data instruction containing wire attribute information and the associated weight-sensing tray network address, and drives the RFID tag printer to write the information into blank RFID tags. S4: Read the RFID tag affixed to the pallet using a handheld terminal, and query the real-time inventory data from the data processing center based on the read pallet network address.

10. The method according to claim 9, characterized in that, In step S2, the specific steps for the data processing center to calculate the change in inventory quantity include: calculating the absolute value of the weight change |ΔM|; dividing |ΔM| by the standard weight of a single roll Wu to obtain the quotient; and rounding the quotient to the nearest integer to obtain the change in inventory quantity N in integer form.

Images