A warehouse management and control method and system based on consumable complete equipment

Abstract

The present application belongs to the technical field of automated warehousing, and particularly relates to a warehouse management and control method and system based on consumable complete equipment. The system comprises a management system, a dispatch control system and an access system for transferring equipment; the management system is used for obtaining equipment information of a to-be-shelved equipment of a complete equipment that passes a qualification detection; if the equipment information exists in a pre-obtained shelving list, the equipment is allocated a storage location according to a pre-set storage rule, so that each box equipment belonging to the same complete equipment is allocated to adjacent or same storage locations; if the equipment information does not exist in the pre-obtained shelving list, shelving is stopped; the dispatch control system is used for detecting whether the to-be-shelved equipment is qualified; and the access system is controlled to store the equipment according to the allocated storage location, so as to complete shelving of the equipment. The present application solves the technical problem of low management efficiency caused by separate storage of components of a complete equipment in the prior art.

Description

Technical Field

[0001] This invention belongs to the field of automated warehousing technology, specifically relating to a warehousing management method and system based on complete sets of consumable equipment. Background Technology

[0002] Many enterprises currently face problems such as inefficiency in warehouse management, cumbersome and disorganized data management, lack of automation technology, or insufficient intelligent identification equipment, low data entry accuracy, and high labor costs. With the continuous advancement of information technology, warehouse management has become more flexible, and electronic information technology can significantly improve the efficiency of materials management. Integrating intelligent, digital, and information-based technologies into the materials and warehouse management process optimizes business processes, standardizes operational management, and provides managers with accurate, timely, and reliable management and operational information.

[0003] For example, the Chinese invention patent application with publication number CN120328011A and publication date of July 18, 2025, discloses an automated warehouse management system. This system includes an inventory management module for real-time recording or updating of warehouse goods entry and exit information, a goods storage module for feeding back goods storage location information to the inventory management module, a goods handling module for moving goods, a data acquisition and transmission module for obtaining real-time warehouse status, and a warehouse analysis module for performing in-depth analysis based on warehouse status information and updating the inventory management module. This solution can achieve intelligent and digital warehouse management. However, in actual production, some equipment is often used in sets. If the components of these sets of equipment are stored individually, multiple and cumbersome storage and retrieval operations are required during unloading and loading, affecting efficiency. Furthermore, stacker cranes and other storage and retrieval mechanisms may require multiple operations to retrieve all components of a set of equipment, resulting in low outbound efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a warehouse management method and system based on complete sets of consumable equipment, so as to solve the technical problem of low management efficiency caused by the separate storage of components of complete sets of equipment in the prior art.

[0005] To solve the above-mentioned technical problems, the present invention provides a technical solution for a warehouse management and control method based on complete sets of consumable equipment: a warehouse management and control method based on complete sets of consumable equipment, the method including a method for putting equipment on shelves: S1. Obtain equipment information for complete sets of equipment that have passed qualified testing and are ready to be installed; S2. If the equipment information exists in the pre-obtained shelving list, then the equipment is allocated a storage location according to the pre-set storage rules so that each box of equipment belonging to the same set of equipment is allocated to an adjacent or the same storage location. If the equipment information is not found in the pre-obtained listing list, the listing will be suspended. S3. Store the equipment according to the assigned storage location to complete the shelving of the equipment.

[0006] The beneficial effects of the above technical solution are as follows: The equipment management method provided by this invention centrally stores all boxes of equipment belonging to the same complete set of equipment during the equipment shelving stage. That is, the storage locations of the boxes of equipment within the same set are adjacent or identical (multi-depth storage locations, such as double-depth storage locations). On the one hand, unified management of the complete set of equipment is possible during shelving; on the other hand, when the equipment is removed from the shelving, stacker cranes and other storage and retrieval machines can easily retrieve and place the complete set of equipment nearby, greatly improving the efficiency of equipment removal and avoiding the low management efficiency caused by storing individual components of the complete set of equipment separately. This invention solves the technical problem of low management efficiency caused by the separate storage of components of complete sets of equipment in the prior art.

[0007] Furthermore, the storage rules include: if the equipment is already bound to a storage location, then the corresponding bound storage location is assigned to the equipment; If the equipment is not bound to a storage location and it is the first piece of equipment to be put on the shelf in the complete set of equipment, then a storage location will be assigned to the equipment and bound to it, and storage locations will be reserved for the other equipment to which the complete set of equipment belongs. If the equipment is not bound to a storage location and is not the first piece of equipment to be shelved in its complete set of equipment, then the equipment will be assigned its corresponding reserved storage location and bound to the storage location.

[0008] Furthermore, the method also includes a method for removing equipment from shelves: 1) Generate a delisting order based on the equipment information to be delisted; determine the storage location of the equipment to be delisted based on the delisting order; generate a delisting instruction based on the storage location of the equipment to be delisted and issue it; the delisting instruction includes a batch delisting instruction for delisting each box of equipment of the same complete set of equipment in batches and a single box of equipment and a separate delisting instruction for delisting non-complete sets of equipment separately. 2) According to the removal instruction, the storage and retrieval system sequentially transfers the equipment to be removed from the removal instruction to the transfer platform until all the equipment in the removal instruction has been transferred to the transfer platform, so that the equipment can be manually lifted off the transfer platform by a crane or forklift to complete the removal.

[0009] Furthermore, the method also includes a fault recovery method when a fault occurs during the equipment loading or unloading process: when a fault occurs, if the storage and retrieval system used to transfer the equipment has equipment, the equipment is transferred to the docking station. Then, if the failure occurs during the uploading process, the uploading method will be restarted; if the failure occurs during the delisting process, the delisting will be forcibly completed.

[0010] Furthermore, the storage rules also include: if the equipment type in the shelving list is new, usable, or empty, then a storage location in the formal storage area is allocated to the equipment; if the equipment type in the shelving list is faulty, temporarily stored, or scrapped, then a storage location in the temporary storage area is allocated to the equipment.

[0011] The present invention also provides a technical solution for a warehouse management and control system based on complete sets of consumable equipment: a warehouse management and control system based on complete sets of consumable equipment, including a management system, a scheduling and control system, and a storage and retrieval system for transferring equipment; The management system is used to: obtain equipment information of complete sets of equipment that have passed the qualified inspection and are ready to be put on the shelf; if the equipment information exists in the pre-obtained shelf list, then allocate a storage location for the equipment according to the pre-set storage rules so that each box of equipment belonging to the same complete set of equipment is allocated to an adjacent or the same storage location; if the equipment information does not exist in the pre-obtained shelf list, then stop the shelfing. The scheduling and control system is used to: detect whether the equipment to be put on the shelf is qualified; and control the storage and retrieval system to store the equipment according to the allocated storage location, so as to complete the putting of the equipment on the shelf.

[0012] The beneficial effects of the above technical solution are as follows: The control system for complete sets of equipment provided by this invention centrally stores all boxes of equipment belonging to the same complete set of equipment during the equipment shelving stage. That is, the storage locations of each box of equipment within the same set of equipment are adjacent or identical (multi-depth storage locations, such as double-depth storage locations). On the one hand, unified management of the complete sets of equipment can be carried out during shelving; on the other hand, when the equipment is removed from the shelving, stacker cranes and other storage and retrieval machines can easily retrieve and place the complete sets of equipment nearby, greatly improving the efficiency of equipment removal and avoiding the low management efficiency caused by storing each component of the complete set of equipment separately. This invention solves the technical problem of low management efficiency caused by storing components of complete sets of equipment separately in the prior art.

[0013] Furthermore, the storage rules include: if the equipment is already bound to a storage location, then the corresponding bound storage location is assigned to the equipment; If the equipment is not bound to a storage location and it is the first piece of equipment to be put on the shelf in the complete set of equipment, then a storage location will be assigned to the equipment and bound to it, and storage locations will be reserved for the other equipment to which the complete set of equipment belongs. If the equipment is not bound to a storage location and is not the first piece of equipment to be shelved in its complete set of equipment, then the equipment will be assigned its corresponding reserved storage location and bound to the storage location.

[0014] Furthermore, a delisting order is generated based on the equipment information to be delisted; and the storage location of the equipment to be delisted is determined based on the delisting order; a delisting instruction is generated based on the storage location of the equipment to be delisted and sent to the dispatch control system; the delisting instruction includes a batch delisting instruction for delisting each box of equipment of the same complete set of equipment in batches and a single delisting instruction for delisting single box of equipment of complete set of equipment and individual delisting instruction for non-complete set of equipment. The scheduling and control system is also used to: control the storage and retrieval system to sequentially transfer the equipment to be removed from the rack to the receiving platform according to the removal instruction, until all the equipment in the removal instruction is transferred to the receiving platform, so that the equipment on the receiving platform can be lifted away by a crane or forklift to complete the removal.

[0015] Furthermore, the scheduling and control system is also used to: when a fault occurs, determine whether the access system has equipment; if the access system has equipment, transfer the equipment to the docking station; when a fault occurs during the shelving process and the equipment at the access system has been transferred to the docking station, restart the shelving process. The management system is also used to: forcibly complete the removal process after a failure occurs during the removal process and the equipment at the access system has been transferred to the docking station.

[0016] Furthermore, the storage rules also include: if the equipment type in the shelving list is new, usable, or empty, then a storage location in the formal storage area is allocated to the equipment; if the equipment type in the shelving list is faulty, temporarily stored, or scrapped, then a storage location in the temporary storage area is allocated to the equipment. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the system architecture of the warehouse management and control system based on complete sets of consumable equipment according to the present invention; Figure 2 This is a flowchart illustrating the shelving process of an implementation method of the warehouse management system based on complete sets of consumable equipment according to the present invention. Figure 3 This is a flowchart illustrating the deshopping process of the warehouse management system based on complete sets of consumable equipment according to the present invention. Figure 4 This is a fault recovery flowchart for an implementation of the warehouse management and control system based on complete sets of consumable equipment according to the present invention. Detailed Implementation

[0018] The complete equipment management system provided by this invention centrally stores all boxes of equipment belonging to the same complete equipment set during the equipment shelving stage. This means that the storage locations for boxes of equipment within the same complete equipment set are adjacent or identical (multi-depth storage locations, such as double-depth storage locations). This allows for unified management of the complete equipment set during shelving; furthermore, when the equipment is removed from the shelving, stacker cranes and other storage and retrieval machines can easily retrieve and place the complete equipment from nearby locations, greatly improving the efficiency of equipment removal and avoiding the low management efficiency caused by storing individual components of the complete equipment set separately. This invention solves the technical problem of low management efficiency caused by the separate storage of components of complete equipment sets in the prior art.

[0019] Implementation method of warehouse management system based on complete sets of consumable equipment: This invention addresses the storage and turnover of consumable equipment sets by proposing a warehouse management and control system for such equipment. This system enables information management and location allocation throughout the entire lifecycle of the equipment, and achieves high reliability in data processing through database backup, fault handling, and redundant disk arrays. It includes an equipment storage and retrieval system for storing and loading / unloading equipment, and a scheduling and control system for coordinating the storage and retrieval system to complete these processes. This significantly improves the speed of response to equipment usage needs, facilitates management, and enhances the supply guarantee capability of the equipment.

[0020] like Figure 1 As shown, the control system includes a management system, a scheduling and control system, and an access system.

[0021] The management system includes an explosion-proof control cabinet and the computer inside it, an information barcode reader as one of the computer input devices, and management system software deployed on the computer. The management system can automatically complete equipment barcode scanning and identification, information recording, and task formulation and issuance.

[0022] The dispatch control system includes an explosion-proof central control cabinet installed at the docking station and the central control equipment arranged inside it, automatic detection equipment for detecting equipment, and PLC control software deployed on the central control equipment. The dispatch control system can automatically control the entrance and exit detection equipment to complete the detection of equipment weight and presence or absence, automatically issue instructions to control the movement of the stacker crane, and complete the transfer and storage of equipment between the docking station and the storage equipment location.

[0023] The storage and retrieval system includes an explosion-proof stacker crane for storing and retrieving equipment, as well as storage and retrieval system software deployed on the stacker crane controller. It mainly consists of a retrieval mechanism, a safety mechanism, a frame, electrical equipment, etc., and has three-dimensional motion retrieval and placement functions, enabling it to complete the storage and retrieval of equipment.

[0024] Specifically, the management system's homepage displays cargo location information and uses colors to distinguish the usage status of each location. Double-clicking a cargo location allows you to view the packing list.

[0025] The following section uses the listing and delisting processes as examples to explain in detail the interaction relationships between the various subsystems within the control system.

[0026] like Figure 2 As shown, the listing process includes the following steps: 1) Import the equipment information to be put on the shelf in this batch into the management system and generate a shelf order.

[0027] Specifically, equipment information can be imported through either a distribution from a higher-level system or local import (such as from a CD).

[0028] Regarding the format of equipment information, the management system supports importing box information and packing lists in Excel file format, as well as manually adding box information and packing lists to generate shelving orders.

[0029] In the order list, you can select the order type. The options are: empty box, new product, usable, faulty, scrapped, and temporary storage.

[0030] 2) The equipment to be put on the rack is manually lifted onto the docking platform at the entrance and exit by a crane or forklift; the operator presses the start button on the docking platform.

[0031] 3) The equipment on the dispatch control system docking station is inspected. After passing the cargo detection, height detection and overweight detection (that is, there is equipment on the docking station and the height and weight of the equipment do not exceed the set limits), the dispatch control system sends a barcode scanner activation message to the management system.

[0032] 4) After receiving the message, the management system automatically reads the information code on the device using a barcode scanner (i.e., the aforementioned information reading device) and records the equipment information; then it compares whether the equipment information is in the aforementioned shelf list. If the item exists, the management system sends a barcode scanner task reception message to the dispatch control system. If the item does not exist (i.e., the equipment information is not in the aforementioned shelf list), the management system sends a management system account status message to the dispatch control system, terminating the shelf process.

[0033] 5) The management system automatically allocates storage locations (complete sets of equipment are stored centrally, or they can be stored in single-depth storage locations according to priority) and calculates instructions. It analyzes the received equipment status information messages to determine if the instructions can be issued. After verification (i.e., the stacker crane is in a working state), it sends a task issuance message to the scheduling control system to transmit the allocated storage location to the scheduling control system.

[0034] Specifically, the equipment status information message is sent from the dispatch control system to the management system.

[0035] Specifically, the management system allocates storage locations according to the following storage rules: equipment is stored in fixed locations in groups of sets, that is, each set of equipment is stored in a fixed location. For example, a set of four boxes is stored in two adjacent locations in a double-deep storage area; a set of three boxes is stored nearby according to the principle of priority based on layer or row.

[0036] In addition, when the first box of equipment for each set is put on the shelf, storage locations are allocated according to the principle that complete sets of equipment need to be stored together. Storage locations are reserved for the same set of equipment that has not yet been put on the shelf, and the status of the reserved storage locations is set to reserved. The storage locations are then bound to the equipment locations using the identification marks of the complete sets of equipment.

[0037] The storage location status is normal, and the storage location binding is not empty, indicating that the storage location is already bound to equipment. To unbind, you need to unbind all storage locations by set, and then unbind the relationships on the fault recovery page. The storage location will be reassigned when the equipment is returned to the warehouse.

[0038] Storage locations are divided into temporary and formal storage areas. Equipment classified as new, usable, or empty containers is automatically assigned to the formal storage area. Equipment classified as faulty, temporarily stored, or scrapped is automatically assigned to the temporary storage area. Locations are automatically assigned based on priority, but users can also manually enter a specified storage location before shelving. Sets of four containers and sets of three containers are stored together. The centralized storage area cannot be used for both. After equipment is removed from the shelving and returned to the warehouse, a usable equipment shelving slip is automatically generated, and the equipment is shelved to its designated storage location (the original bound storage location).

[0039] 6) After receiving the assigned storage location, the dispatch control system sends a task receiving message to the management system and sends a racking instruction to the storage and retrieval system. Upon receiving the racking instruction, the storage and retrieval system transfers the equipment from the docking station to the assigned storage location to execute the racking process.

[0040] 7) After the storage and retrieval system completes its work, it reports the completion status of the task to the scheduling and control system. If the task is completed, the scheduling and control system sends a task completion message to the management system. If the task is not completed, the scheduling and control system sends a task failure message.

[0041] 8) The management system sends a message to the scheduling and control system indicating that the task has been completed, and the on-the-shelf process ends.

[0042] The control system sends loading and unloading instructions for the corresponding storage locations to the stacker crane and connecting platform via internal interface commands. It also receives real-time information on the stacker crane's operating mode, status, and alarms from the connecting platform, displaying this information graphically on the monitoring interface. Furthermore, it has the capability to handle fault procedures when tasks are completed or fail.

[0043] The control system schedules the storage and retrieval equipment. Based on the feedback signals from the position detection switches of the field equipment, the programmable logic controller of the stacker crane performs logical analysis and processing, and issues control commands to the field equipment to complete the vertical ascent / descent and horizontal forward / backward movement of the storage and retrieval equipment (stacker crane), and to complete the telescopic mechanism to retrieve or unload goods at the target location; it completes a series of sequential action control of the field equipment to complete the storage and retrieval task.

[0044] The delisting process is basically the reverse of the listing process. For example... Figure 3 As shown, the delisting process includes the following steps: 1) First, enter the equipment information to be removed from the management system and generate a removal order.

[0045] When generating a delisting order, the system offers filtering options by time, box QR code, etc., to find equipment that meets the criteria. Delisting orders can also be generated in batches by equipment sets.

[0046] The control system in this implementation supports batch removal of complete sets of equipment (i.e., continuous removal). Continuous removal is only allowed for complete sets of equipment; continuous removal of incomplete sets is not permitted. A maximum of four boxes of a complete set of equipment can be removed continuously, but less than four boxes is permissible. The "four boxes" here is determined based on the maximum number of boxes per single complete set of equipment.

[0047] 2) When an administrator clicks the "Remove from Shelf" button in the management system, the system automatically allocates storage locations (i.e., determines the storage location of the equipment to be removed from shelf based on the removal order) and calculates the instruction. It analyzes the received equipment status information messages to determine if the instruction can be issued. After verification, it sends a task issuance message (i.e., sends the removal instruction) to the scheduling and control system. The removal instruction includes batch removal instructions for removing all boxes of equipment from the same complete set of equipment, and individual removal instructions for removing single boxes of equipment from complete sets of equipment and for removing non-complete sets of equipment.

[0048] 3) When the dispatch control system receives the unloading instruction, it controls the storage and retrieval system to execute the unloading process. The storage and retrieval system automatically retrieves the equipment onto the transfer platform according to the programmed process. The equipment on the transfer platform is then manually lifted away by a crane or forklift.

[0049] Then repeat step 3) above until all the equipment is removed from the shelves.

[0050] 4) The storage and retrieval system reports the task completion status; if the destocking is completed, the dispatch control system sends a task completion message to the management system; if the destocking fails, the dispatch control system sends a task failure message; the management system sends a message to the dispatch control system that the task completion message has been received, and the destocking process ends.

[0051] The system manages inventory management, enabling one-click inventory control and optimizing storage and retrieval. Batch inventory removal is possible, but continuous inventory removal is only allowed for complete sets of equipment (i.e., batch inventory removal commands). Incomplete sets of equipment cannot be continuously removed (only individual inventory removal commands are permitted). A maximum of four boxes of a complete set can be removed consecutively, but less than four boxes are permissible. While equipment is being removed from the shelves, inventory removal tasks cannot be issued. If an inventory removal task is issued, the central control system (i.e., the scheduling and control system) will not accept it, and the inventory removal task will be considered in progress by default. Similarly, while equipment is being installed, inventory removal tasks cannot be issued. If an inventory removal task is issued, the central control system will not accept it, and the inventory removal task will be considered in progress by default. By default, if there are inventory removal or inventory removal tasks in progress, any subsequent inventory removal or installation operations will be invalid. Unfinished tasks will be handled in the task management section.

[0052] The management system records shelving and inventory entries, which can be queried and exported. The database is backed up to prevent accidental data loss. A paper copy of the accounts is provided to prevent data loss in case of computer failure. A redundant disk array ensures high reliability in data processing. The management system also has inventory management functions: when less than 10% of the boxes in the automated warehouse are stored (this can be set manually), an inventory alarm will alert the system that the inventory has reached its lower limit.

[0053] When a fault occurs, execute the fault recovery procedure, such as... Figure 4 As shown, the fault recovery process includes the following steps: First, restore the storage and retrieval system and the dispatch control system to standby mode. Determine if the storage and retrieval system has equipment (i.e., whether equipment is being added / removed). If not, the fault recovery process ends. If the storage and retrieval system has equipment, the dispatch control system directs the system to the docking station to unload the equipment and place it there (i.e., forcing the storage and retrieval system to execute the removal process); alternatively, the equipment can be manually transferred from the storage and retrieval system to the docking station. Then, depending on whether the fault occurred during the adding or removing process, continue with the corresponding procedure: If the fault occurs during the shelving process, the operator will restart the shelving button on the docking station and, after passing the goods detection, height detection, and overweight detection, enable the storage and retrieval system to execute the shelving process, transfer the equipment from the docking station to the designated storage location, and report the completion status after shelving is completed. If shelving is completed, the fault recovery is complete.

[0054] If the malfunction occurs during the unloading process, since the equipment has already been moved to the docking station, the equipment can simply be manually removed from the docking station using an overhead crane or forklift. Therefore, the task can be forced to complete directly in the management system.

[0055] Implementation method of warehouse management and control based on complete sets of consumable equipment: A warehouse management method based on complete sets of consumable equipment, such as Figure 2 As shown, the method includes the method for loading equipment: S1. Obtain equipment information for complete sets of equipment that have passed qualified testing and are ready to be installed.

[0056] Import the equipment information for this batch that needs to be put on the shelf into the management system and generate a shelf order.

[0057] Specifically, equipment information can be imported through either a distribution from a higher-level system or local import (such as from a CD).

[0058] Regarding the format of equipment information, the management system supports importing box information and packing lists in Excel file format, as well as manually adding box information and packing lists to generate shelving orders.

[0059] In the order list, you can select the order type. The options are: empty box, new product, usable, faulty, scrapped, and temporary storage.

[0060] The equipment to be shelved is manually hoisted onto the vertical entrance and exit docking platform by a crane or forklift; the operator presses the shelving start button on the docking platform.

[0061] The dispatch control system detects the equipment on the docking station. After passing the cargo detection, height detection, and overweight detection (i.e., there is equipment on the docking station and the height and weight of the equipment do not exceed the set limits), the dispatch control system sends a barcode scanner activation message to the management system.

[0062] S2. If the equipment information exists in the pre-obtained putaway list, then allocate a storage location for the equipment according to the pre-set storage rules, so that each box of equipment belonging to the same complete set of equipment is assigned to an adjacent or the same storage location. If the equipment information does not exist in the pre-obtained putaway list, then putaway is stopped.

[0063] The storage rules include: if the equipment is already bound to a storage location, then the equipment is assigned its corresponding bound storage location; if the equipment is not bound to a storage location and is the first piece of equipment to be shelved in its complete set of equipment, then the equipment is assigned a storage location and bound, and storage locations are reserved for the remaining equipment to which the complete set of equipment belongs; if the equipment is not bound to a storage location and is not the first piece of equipment to be shelved in its complete set of equipment, then the equipment is assigned its corresponding reserved storage location and bound.

[0064] The storage rules also include: if the equipment type in the putaway order is new, usable, or empty, then a storage location in the formal storage area will be allocated to the equipment; if the equipment type in the putaway order is faulty, temporarily stored, or scrapped, then a storage location in the temporary storage area will be allocated to the equipment.

[0065] After receiving the message, the management system automatically reads the information code on the device using a barcode scanner (i.e., the aforementioned information reading device) and records the equipment information. It then compares the equipment information with the aforementioned inventory list. If the item exists, the management system sends a barcode scanner task reception message to the dispatch control system. If the item does not exist (i.e., the equipment information is not in the aforementioned inventory list), the management system sends a management system inventory status message to the dispatch control system, terminating the inventory process.

[0066] The management system automatically allocates storage locations (complete sets of equipment can be stored centrally, or stored in single-depth storage locations according to priority) and calculates instructions. It analyzes the received equipment status information messages to determine if the instructions can be issued. Once verified (i.e., the stacker crane is in a working state), it sends a task issuance message to the scheduling control system to distribute the allocated storage locations.

[0067] Specifically, the equipment status information message is sent from the dispatch control system to the management system.

[0068] Specifically, the management system allocates storage locations according to the following storage rules: equipment is stored in fixed locations in groups of sets, that is, each set of equipment is stored in a fixed location. For example, a set of four boxes is stored in two adjacent locations in a double-deep storage area; a set of three boxes is stored nearby according to the principle of priority based on layer or row.

[0069] In addition, when the first box of equipment for each set is put on the shelf, storage locations are allocated according to the principle that complete sets of equipment need to be stored together. Storage locations are reserved for the same set of equipment that has not yet been put on the shelf, and the status of the reserved storage locations is set to reserved. The storage locations are then bound to the equipment locations using the identification marks of the complete sets of equipment.

[0070] The storage location status is normal, and the storage location binding is not empty, indicating that the storage location is already bound to equipment. To unbind, you need to unbind all storage locations by set, and then unbind the relationships on the fault recovery page. The storage location will be reassigned when the equipment is returned to the warehouse.

[0071] Storage locations are divided into temporary and formal storage areas. Equipment classified as new, usable, or empty containers is automatically assigned to the formal storage area. Equipment classified as faulty, temporarily stored, or scrapped is automatically assigned to the temporary storage area. Locations are automatically assigned based on priority, but users can also manually enter a specified storage location before shelving. Sets of four containers and sets of three containers are stored together. The centralized storage area cannot be used for both. After equipment is removed from the shelving and returned to the warehouse, a usable equipment shelving slip is automatically generated, and the equipment is shelved to its designated storage location (the original bound storage location).

[0072] S3. Store the equipment according to the assigned storage location to complete the shelving of the equipment.

[0073] After receiving the assigned storage location, the dispatch control system sends a task reception message to the management system and a racking instruction to the storage and retrieval system. Upon receiving the racking instruction, the storage and retrieval system transfers the equipment from the docking station to the assigned storage location to execute the racking process.

[0074] like Figure 3 As shown, the method includes a procedure for removing equipment from the shelf: 1) Generate a delisting order based on the equipment information to be delisted; determine the storage location of the equipment to be delisted based on the delisting order; generate and issue a delisting instruction based on the storage location of the equipment to be delisted; the delisting instruction includes a batch delisting instruction for delisting each box of equipment of the same complete set of equipment in batches and a single delisting instruction for delisting single box of equipment of complete set of equipment and individual delisting instruction for non-complete set of equipment.

[0075] First, enter the equipment information to be removed from the management system and generate a removal order.

[0076] When generating a delisting order, the system offers filtering options by time, box QR code, etc., to find equipment that meets the criteria. Delisting orders can also be generated in batches by equipment sets.

[0077] This implementation supports batch removal from shelves (i.e., continuous removal). Continuous removal is for complete sets of equipment; continuous removal of incomplete sets of equipment is not allowed. A maximum of four boxes of a complete set of equipment can be removed continuously, but less than four boxes is permitted. The "four boxes" here is determined based on the maximum number of boxes for a single complete set of equipment.

[0078] When an administrator clicks the "Remove from Shelf" button in the management system, the system automatically allocates storage locations (i.e., determines the storage location of the equipment to be removed from shelf based on the removal order) and calculates the instruction. It analyzes the received equipment status information message to determine if the instruction can be issued. If verified, it sends a task issuance message (i.e., sends the removal instruction) to the dispatch control system.

[0079] 2) According to the removal instruction, the storage and retrieval system sequentially transfers the equipment to be removed from the removal instruction to the transfer platform until all the equipment in the removal instruction has been transferred to the transfer platform, so that the equipment can be manually lifted off the transfer platform by a crane or forklift to complete the removal.

[0080] When the dispatch control system receives the unloading instruction, it controls the storage and retrieval system to execute the unloading process. The storage and retrieval system automatically retrieves the equipment onto the transfer platform according to the programmed process. The equipment on the transfer platform is then manually lifted away by a crane or forklift.

[0081] Then repeat the above steps until all the equipment has been removed from the shelves.

[0082] The storage and retrieval system reports the task completion status; if the destocking is completed, the dispatch control system sends a task completion message to the management system; if the destocking fails, the dispatch control system sends a task failure message; the management system sends a message to the dispatch control system that the task completion message has been received, and the destocking process ends.

[0083] like Figure 4 As shown, the method also includes a fault recovery method when a fault occurs during the equipment mounting or unmounting process; the fault recovery method includes: when a fault occurs, if the storage and retrieval system used to transfer the equipment has equipment, then the equipment is transferred to the docking station; then, if the fault occurs during the mounting process, the mounting method is restarted; if the fault occurs during the unmounting process, the unmounting is forcibly completed.

[0084] When a fault occurs, the fault recovery process is executed: First, the access system and dispatch control system are restored to standby status. The system checks if there is equipment in the access system (i.e., whether equipment is being added / removed). If not, the fault recovery process ends. If there is equipment in the access system, the dispatch control system directs the access system to the docking station to unload the equipment and place it there (i.e., forcing the access system to execute the removal process); alternatively, the equipment can be manually transferred from the access system to the docking station. Then, depending on whether the fault occurred during the adding or removing process, the corresponding process continues. If the fault occurs during the shelving process, the operator will restart the shelving button on the docking station and, after passing the goods detection, height detection, and overweight detection, enable the storage and retrieval system to execute the shelving process, transfer the equipment from the docking station to the designated storage location, and report the completion status after shelving is completed. If shelving is completed, the fault recovery is complete.

[0085] If the malfunction occurs during the unloading process, since the equipment has already been moved to the docking station, the equipment can simply be manually removed from the docking station using an overhead crane or forklift. Therefore, the task can be forced to complete directly in the management system.

[0086] This invention has the following characteristics: For scenarios involving the storage and turnover of consumable equipment sets, this invention proposes a control system and management methods. It features automated storage and an equipment management system for managing information throughout the entire lifecycle of the equipment, allocating storage locations, and ensuring high data reliability through database backup, fault handling, and redundant disk arrays. An equipment storage and retrieval system handles equipment storage and removal / removal. A scheduling and control system coordinates the equipment storage and retrieval system to complete these processes. This improves the speed of response to equipment usage needs, facilitates management, and enhances the supply guarantee capability of the equipment.

[0087] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still make modifications to the technical solutions described in the foregoing embodiments without creative effort, or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A warehouse management and control method based on complete sets of consumable equipment, characterized in that, This method includes the method for loading equipment: S1. Obtain equipment information for complete sets of equipment that have passed qualified testing and are ready to be installed; S2. If the equipment information exists in the pre-obtained shelving list, then the equipment is allocated a storage location according to the pre-set storage rules so that each box of equipment belonging to the same set of equipment is allocated to an adjacent or the same storage location. If the equipment information is not found in the pre-obtained listing list, the listing will be stopped; S3. Store the equipment according to the assigned storage location to complete the shelving of the equipment.

2. The warehouse management method based on complete sets of consumable equipment according to claim 1, characterized in that, The storage rules include: if the equipment is already bound to a storage location, then the corresponding bound storage location will be assigned to the equipment; If the equipment is not bound to a storage location and it is the first piece of equipment to be put on the shelf in the complete set of equipment, then a storage location will be assigned to the equipment and bound to it, and storage locations will be reserved for the other equipment to which the complete set of equipment belongs. If the equipment is not bound to a storage location and is not the first piece of equipment to be shelved in its complete set of equipment, then the equipment will be assigned its corresponding reserved storage location and bound to the storage location.

3. The warehouse management method based on complete sets of consumable equipment according to claim 1, characterized in that, The method also includes methods for removing equipment from shelves: 1) Generate a delisting order based on the equipment information to be delisted; determine the storage location of the equipment to be delisted based on the delisting order; generate a delisting instruction based on the storage location of the equipment to be delisted and issue it; the delisting instruction includes a batch delisting instruction for delisting each box of equipment of the same complete set of equipment in batches and a single box of equipment and a separate delisting instruction for delisting non-complete sets of equipment separately. 2) According to the removal instruction, the storage and retrieval system sequentially transfers the equipment to be removed from the removal instruction to the transfer platform until all the equipment in the removal instruction has been transferred to the transfer platform, so that the equipment can be manually lifted off the transfer platform by a crane or forklift to complete the removal.

4. The warehouse management method based on complete sets of consumable equipment according to claim 3, characterized in that, The method also includes a fault recovery method when a fault occurs during the equipment loading or unloading process: when a fault occurs, if the storage and retrieval system used to transfer the equipment has equipment, the equipment is transferred to the docking station. Then, if the failure occurs during the uploading process, the uploading method will be restarted; if the failure occurs during the delisting process, the delisting will be forcibly completed.

5. The warehouse management method based on complete sets of consumable equipment according to claim 1 or 2, characterized in that, The storage rules also include: if the equipment type in the shelving list is new, usable, or empty, then a storage location in the formal storage area will be allocated to the equipment; if the equipment type in the shelving list is faulty, temporarily stored, or scrapped, then a storage location in the temporary storage area will be allocated to the equipment.

6. A warehouse management and control system based on complete sets of consumable equipment, characterized in that, This includes management systems, scheduling and control systems, and storage and retrieval systems for transferring equipment; The management system is used to: obtain equipment information of complete sets of equipment that have passed the qualified inspection and are ready to be put on the shelf; if the equipment information exists in the pre-obtained shelf list, then allocate a storage location for the equipment according to the pre-set storage rules so that each box of equipment belonging to the same complete set of equipment is allocated to an adjacent or the same storage location; if the equipment information does not exist in the pre-obtained shelf list, then stop the shelfing. The scheduling and control system is used to: detect whether the equipment to be put on the shelf is qualified; and control the storage and retrieval system to store the equipment according to the allocated storage location, so as to complete the putting of the equipment on the shelf.

7. The warehouse management and control system based on complete sets of consumable equipment according to claim 6, characterized in that, The storage rules include: if the equipment is already bound to a storage location, then the corresponding bound storage location will be assigned to the equipment; If the equipment is not bound to a storage location and it is the first piece of equipment to be put on the shelf in the complete set of equipment, then a storage location will be assigned to the equipment and bound to it, and storage locations will be reserved for the other equipment to which the complete set of equipment belongs. If the equipment is not bound to a storage location and is not the first piece of equipment to be shelved in its complete set of equipment, then the equipment will be assigned its corresponding reserved storage location and bound to the storage location.

8. The warehouse management and control system based on complete sets of consumable equipment according to claim 6, characterized in that, The management system is also used to: generate a delisting order based on the equipment information to be delisted; determine the storage location of the equipment to be delisted based on the delisting order; generate a delisting instruction based on the storage location of the equipment to be delisted and send it to the dispatch control system; the delisting instruction includes a batch delisting instruction for delisting each box of equipment of the same complete set of equipment and a single delisting instruction for delisting a single box of equipment of a complete set of equipment and a separate delisting instruction for delisting non-complete sets of equipment. The scheduling and control system is also used to: control the storage and retrieval system to sequentially transfer the equipment to be removed from the rack to the receiving platform according to the removal instruction, until all the equipment in the removal instruction is transferred to the receiving platform, so that the equipment on the receiving platform can be lifted away by a crane or forklift to complete the removal.

9. The warehouse management and control system based on complete sets of consumable equipment according to claim 8, characterized in that, The scheduling and control system is also used to: when a fault occurs, determine whether the access system has equipment; if the access system has equipment, transfer the equipment to the docking station; when a fault occurs during the shelving process and the equipment at the access system has been transferred to the docking station, restart the shelving process. The management system is also used to: forcibly complete the removal process after a failure occurs during the removal process and the equipment at the access system has been transferred to the docking station.

10. The warehouse management and control system based on complete sets of consumable equipment according to claim 6, characterized in that, The storage rules also include: if the equipment type in the shelving list is new, usable, or empty, then a storage location in the formal storage area will be allocated to the equipment; if the equipment type in the shelving list is faulty, temporarily stored, or scrapped, then a storage location in the temporary storage area will be allocated to the equipment.

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