Latent agv-forklift agv-four-way vehicle warehouse linkage warehousing system of paper adapter factory and operation method thereof

Abstract

This invention discloses a warehousing system and its operation method adapted for paper mills, featuring a hidden AGV-forklift AGV-four-way automated storage and retrieval system (AS / RS). The warehousing system includes: an overhead hidden AGV transfer module: the hidden AGVs can precisely connect with the printing press production line and the discharge ports of supporting equipment, enabling direct multi-channel transfer of goods; a forklift AGV processing module: reach truck AGVs adapt to the multi-scenario handling needs of the downstream processing area; a four-way AS / RS module: employing an "overhead storage, bottom picking" structure to improve space utilization; a collaborative control module: enabling real-time synchronization of task instructions and dynamic path planning for each device; and a WMS system and digital twin fusion module: achieving refined management and visualized intelligent control of the entire warehousing process. This invention can automate the entire process of printing production, downstream processing, and warehousing, significantly improving operational efficiency, reducing cargo loss and material costs, and optimizing warehousing management effectiveness.

Description

Technical Field

[0001] This invention relates to the field of intelligent warehousing and automated logistics technology, specifically to a AGV-forklift-AGV four-way vehicle-assisted vertical warehouse linkage warehousing system adapted for paper mills and its operation method. Background Technology

[0002] As a crucial component of the packaging sector, the paper products industry experiences continuous market demand growth, but traditional paper product manufacturing warehousing and shipping models suffer from numerous pain points:

[0003] 1. Inefficient storage and shipping: Paper products are mostly stored using flat stacking or ordinary shelves. Manual forklift handling and picking operations are inefficient, especially during peak order periods. The shipping speed cannot keep up with market demand, resulting in order backlog and affecting customer satisfaction.

[0004] 2. Low space utilization: Paper products are large in size, and traditional storage methods do not make full use of the vertical space of the warehouse, resulting in waste of storage space and increased operating costs for enterprises.

[0005] 3. Paper products are easily damaged: During manual forklift handling, paper products are easily deformed or damaged due to collisions and squeezing, which affects product quality and increases the defect rate and after-sales costs.

[0006] 4. High shipping error rate: Manual picking relies on experience and is prone to mis-shipment and omissions, especially in scenarios with multiple varieties and small batch orders, making it difficult to guarantee shipping accuracy.

[0007] 5. Information disconnect: Poor communication between warehousing, delivery, production, and sales processes makes it impossible to monitor inventory status and delivery progress in real time, leading to a disconnect between production plans and market demand.

[0008] Existing automated warehousing systems have limitations in paper mill applications: ordinary stacker cranes can only operate along a single aisle, and cross-aisle transfers require auxiliary equipment, resulting in insufficient flexibility; the traditional "goods-to-person" picking mode is difficult to adapt to the special shape and storage requirements of paper products; and most systems have not achieved deep integration with the paper mill's production and logistics systems, failing to meet the paper mill's personalized production and delivery needs. Summary of the Invention

[0009] The purpose of this invention is to propose a holographic AGV-forklift AGV-four-way vehicle-assisted warehouse linkage storage system and its operation method adapted to paper mills. It effectively solves the problems of low warehousing and delivery efficiency, low space utilization, easy damage to paper products, high delivery error rate and information disconnection in traditional paper mills, realizes automation, intelligence and efficiency of paper product warehousing and delivery, and enhances the market competitiveness of paper mills.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0011] The system is compatible with a paper mill's integrated AGV-forklift AGV-four-way vehicle-assisted automated storage and retrieval system, including:

[0012] Top-mounted lurking AGV transfer module: includes a top-mounted lurking AGV with a liftable platform on top. The height of the lifting platform is precisely matched with the output port of the printing machine linkage line and printing supporting equipment. The lifting platform is equipped with a first cargo status detection sensor to monitor the tilt and load status of the cargo in real time. The lurking AGV is equipped with a vision recognition and laser positioning system to automatically identify the specifications and weight of the printed goods.

[0013] Forklift-type AGV processing module: includes a reach truck AGV, on which a telescopic fork is installed, and a second cargo status detection sensor is installed on the fork to monitor the tilt and load status of the cargo in real time;

[0014] Four-way automated storage and retrieval system (AS / RS) module: includes an upper storage area and a lower picking area. The storage area is equipped with four-way vehicles for horizontal and vertical transport of goods. The picking area has a loading port that connects to the shipping channel.

[0015] Collaborative Control Module: The top-mounted lurking AGV transfer module, the forklift AGV processing module, and the four-way vehicles in the four-way vehicle vertical warehouse module are respectively connected to the collaborative control module to establish a two-way communication system and realize real-time synchronization of task instructions. The collaborative control module has a built-in dynamic path algorithm, which is used to adjust the transfer route of the lurking AGV, the operation sequence of the forklift AGV, and the operation path of the four-way vehicles in the four-way vehicle vertical warehouse module in real time according to the inventory status of the four-way vehicle vertical warehouse module, the AGV task queue, and the operation status of the downstream processing area.

[0016] The WMS system and digital twin integration module includes a WMS system and a digital twin platform. The WMS system is connected to the AGVs, forklift AGVs, and four-way vehicle signals to achieve refined management of the entire warehousing process. The digital twin platform is used to build a virtual model that is completely mapped to the physical warehousing system, synchronize the operation data of each module in real time, realize the visual monitoring of the entire warehousing process, optimize AGV path planning and automated warehouse layout by simulating different operating scenarios, and perform predictive maintenance on equipment operating status.

[0017] As a preferred technical solution of the present invention: an anti-slip buffer pad is provided above the lifting platform, and the first cargo status detection sensor is installed on the anti-slip buffer pad.

[0018] As a preferred embodiment of the present invention, the extension range of the forks is 1-1.2m.

[0019] As a preferred technical solution of the present invention: the storage area and the sorting area are respectively provided with shelf units, the shelf units are provided with modular matrix units, longitudinal and transverse track units, standard storage units and support connection units, and are equipped with safety and leveling components, and the surface of the shelf units is coated with antistatic material.

[0020] As a preferred technical solution of the present invention, the dynamic path algorithm in the collaborative control module adopts a path optimization model based on genetic algorithm.

[0021] The operating method for adapting the AGV-forklift-AGV-four-way vehicle-assisted automated storage and retrieval system to a paper mill includes the following steps:

[0022] Step S1: The AGV receives the shipment instruction from the printing machine production line, drives under the discharge port of the production line, raises the lifting platform to lift the goods, and completes the transfer including the pallet.

[0023] Step S2: The lurking AGV transfers the goods to the downstream processing area through the upper-level instructions and sends an inbound instruction to the four-way vehicle-mounted warehouse module;

[0024] Step S3: After the goods are processed in the back-end processing area, the goods are transferred to the high-bay racking area by a forklift AGV and an inbound instruction is sent to the four-way vehicle upright warehouse module;

[0025] Step S4: After receiving the storage instruction from the lurking AGV or forklift AGV, the four-way vehicle vertical warehouse module opens the warehouse door. The collaborative control module begins to plan the storage path and sends the path instructions to the lurking AGV or forklift AGV. The lurking AGV or forklift AGV stores the goods in the upper storage area according to the path instructions. When there is a delivery requirement, the collaborative control module plans the delivery path. The four-way vehicle in the storage area transfers the goods from the upper storage area to the lower picking area according to the delivery path, and completes the delivery by connecting to the delivery channel through the bottom delivery port.

[0026] Step S5: The WMS system and the digital twin fusion module synchronize data from all stages in real time to achieve inventory management, path optimization, and predictive maintenance of equipment.

[0027] As a preferred technical solution of the present invention: In step S1, before lifting the goods, the AGV uses a visual recognition and laser positioning system to identify the specifications and weight of the goods, and adjusts the load-bearing and transfer posture of the lifting platform accordingly.

[0028] As a preferred technical solution of the present invention: In step S3, during the process of transferring goods to the high-level racking area, the forklift AGV monitors the tilt and load-bearing status of the goods in real time. If any abnormality occurs, the operation is stopped immediately and feedback is sent to the WMS system and the digital twin platform.

[0029] As a preferred technical solution of the present invention: in step S4, the storage and retrieval of goods in the four-way vehicle vertical warehouse module adopts the principle of first storage and then exit.

[0030] As a preferred technical solution of the present invention: In step S5, the digital twin platform optimizes the path planning of the lurking AGV and the forklift AGV, as well as the layout of the storage area and sorting area of ​​the automated warehouse, every 24 hours by simulating different operating scenarios.

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0032] This invention can replace traditional manual forklift operations, realize full-process automation of printing production, post-processing and warehousing, greatly improve operational efficiency, reduce cargo damage and material costs, and optimize warehouse management efficiency.

[0033] This invention enables high-density storage, intelligent picking, and automated delivery of paper products, helping paper manufacturers improve warehousing and delivery efficiency and reduce operating costs. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the AGV-forklift-four-way vehicle-integrated warehouse linkage system adapted to paper mills in this invention.

[0035] Figure 2 This is a schematic diagram of the overall structure of the AGV (Automated Guided Vehicle).

[0036] Figure 3 This is the main view of the lurking AGV.

[0037] Figure 4 This is a side view of the lurking AGV.

[0038] Figure 5 This is a rear view of the lurking AGV.

[0039] Figure 6 This is a schematic diagram of the overall structure of a forklift AGV.

[0040] Figure 7 This is a side view of a forklift AGV.

[0041] Figure 8 This is a rear view of the forklift AGV.

[0042] Figure 9 This is a side view of a four-way vehicle.

[0043] Figure 10 This is a top view of a four-way vehicle.

[0044] Figure 11 This is a structural diagram of a shelving unit.

[0045] Figure 12 This is a flowchart of the operation method of the AGV-forklift-four-way vehicle-integrated warehouse system adapted to paper mills in this invention.

[0046] List of reference numerals in the attached diagram:

[0047] 1. Lurking AGV; 2. Lifting platform; 3. First cargo status detection sensor; 4. Forklift AGV; 5. Forks; 6. Second cargo status detection sensor. Detailed Implementation

[0048] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0049] like Figure 1-11 As shown, the proposed invention provides a holographic AGV-forklift AGV-four-way vehicle automated storage and retrieval system adapted for paper mills, comprising:

[0050] Top-mounted lurking AGV transfer module: includes a top-mounted lurking AGV, with a liftable lifting platform (2) above the lurking AGV. The height of the lifting platform (2) is precisely matched with the printing machine linkage line and the material outlet of the printing supporting equipment. A first cargo status detection sensor (3) is installed on the lifting platform (2) to monitor the tilt and load status of the cargo in real time. The lurking AGV is equipped with a visual recognition and laser positioning system to automatically identify the specifications and weight of the printed goods and avoid cargo deformation.

[0051] Forklift-type AGV processing module: includes reach truck AGV, which is equipped with extendable forks (5) to adapt to the multi-scenario handling needs of the downstream processing area and can flexibly handle goods of different specifications; the stacking height is 4.5 meters, which is suitable for the storage requirements of conventional 3-layer racks. The forks (5) are equipped with a second cargo status detection sensor (6) to monitor the tilt and load status of the cargo in real time and prevent the cargo from deforming or falling during the processing.

[0052] Four-way automated storage and retrieval system (AS / RS) module: includes an upper storage area and a lower picking area. The storage area is equipped with four-way vehicles for horizontal and vertical transport of goods. The picking area has a loading port that connects to the shipping channel.

[0053] Collaborative Control Module: The top-mounted lurking AGV transfer module, the forklift AGV processing module, and the four-way vehicles in the four-way vehicle vertical warehouse module are respectively connected to the collaborative control module to establish a two-way communication system and realize real-time synchronization of task instructions. The collaborative control module has a built-in dynamic path algorithm, which is used to adjust the transfer route of the lurking AGV, the operation sequence of the forklift AGV, and the operation path of the four-way vehicles in the four-way vehicle vertical warehouse module in real time according to the inventory status of the four-way vehicle vertical warehouse module, the AGV task queue, and the operation status of the downstream processing area, so as to avoid operation conflicts.

[0054] The WMS system and digital twin integration module includes a WMS system and a digital twin platform. The WMS system connects with AGVs, forklift AGVs, and four-way vehicles to achieve refined management of the entire warehousing process, including functions such as goods entry registration, real-time inventory status updates, intelligent allocation of storage locations, and order processing. It interacts with AGVs and four-way vehicles in real time to ensure the accuracy and timeliness of inventory data. The digital twin platform is used to build a virtual model that is completely mapped to the physical warehousing system, synchronizes the operation data of each module in real time, and realizes visualized monitoring of the entire warehousing process. It optimizes AGV path planning and automated storage and retrieval system (AS / RS) location layout by simulating different operating scenarios, and performs predictive maintenance on equipment operating status to reduce equipment failure rate.

[0055] The lifting platform (2) is equipped with an anti-slip buffer pad to meet the pressure resistance requirements of printed goods. The first goods status detection sensor (3) is installed on the anti-slip buffer pad. The lifting height of the lifting platform (2) can be precisely adjusted according to the height of the printing machine's output port, with an adjustment accuracy of not less than 1mm.

[0056] The forks (5) have a telescopic range of 1-1.2m, which can be adapted to the handling of printed goods of different specifications.

[0057] The storage and sorting areas are each equipped with shelving units. These shelving units have main and sub-aisles to accommodate the storage needs of printed goods. Each shelving unit features a modular matrix unit, longitudinal and transverse rail units, standard storage locations, and supporting connection units, along with safety and leveling components. The surface of each shelving unit is coated with anti-static material to effectively prevent damage to printed goods and equipment.

[0058] The dynamic path algorithm in the collaborative control module adopts a path optimization model based on genetic algorithm, which can complete path planning and adjustment within 1 second.

[0059] like Figure 12 As shown, the operating method of the proposed invention for a paper mill's integrated AGV-forklift AGV-four-way vehicle automated storage and retrieval system includes the following steps:

[0060] Step S1: The AGV receives the shipment instruction from the printing machine's production line, drives under the discharge port of the production line, raises the lifting platform 2 to lift the goods, and completes the transfer including the pallet.

[0061] Before lifting the goods, the AGV uses a visual recognition and laser positioning system to identify the specifications and weight of the goods and adjusts the load-bearing and transfer posture of the lifting platform (2) accordingly to ensure stable transfer of goods.

[0062] Step S2: The lurking AGV transfers the goods to the downstream processing area through the upper-level instructions and sends an inbound instruction to the four-way vehicle-mounted warehouse module;

[0063] Step S3: After the goods are processed in the back-end processing area, the goods are transferred to the high-bay racking area by a forklift AGV and an inbound instruction is sent to the four-way vehicle upright warehouse module;

[0064] During the process of transferring goods to the high-bay racking area, the forklift AGV monitors the tilt and load-bearing status of the goods in real time. If any abnormality occurs, the operation will stop immediately and feedback will be sent to the WMS system and digital twin platform.

[0065] Step S4: After receiving the storage instruction from the lurking AGV or forklift AGV, the four-way vehicle vertical warehouse module opens the warehouse door. The collaborative control module begins to plan the storage path and sends the path instructions to the lurking AGV or forklift AGV. The lurking AGV or forklift AGV stores the goods in the upper storage area according to the path instructions. When there is a delivery requirement, the collaborative control module plans the delivery path. The four-way vehicle in the storage area transfers the goods from the upper storage area to the lower picking area according to the delivery path, and completes the delivery by connecting to the delivery channel through the bottom delivery port.

[0066] The storage and retrieval of goods within the four-way vertical warehouse module follows a first-in, first-out principle to ensure the orderly storage and delivery of goods.

[0067] Step S5: The WMS system and the digital twin fusion module synchronize data from all stages in real time to achieve inventory management, path optimization, and predictive maintenance of equipment;

[0068] The digital twin platform optimizes the path planning of AGVs and forklift AGVs, as well as the layout of storage and sorting areas in the automated warehouse, every hour by simulating different operating scenarios, thereby improving warehousing efficiency.

[0069] It should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any modifications or equivalent changes made based on the technical essence of the present invention shall still fall within the scope of protection claimed by the present invention.

Claims

1. The AGV-fork truck AGV-quadrant vehicle warehouse linkage warehousing system suitable for paper equipment factory, characterized in that, include: Top-mounted lurking AGV transfer module: includes a top-mounted lurking AGV, with a liftable lifting platform (2) above the lurking AGV. The height of the lifting platform (2) is precisely matched with the printing machine linkage line and the material outlet of the printing supporting equipment. A first cargo status detection sensor (3) is installed on the lifting platform (2) to monitor the tilt and load status of the cargo in real time. The lurking AGV is equipped with a visual recognition and laser positioning system to automatically identify the specifications and weight of the printed cargo. Forklift-type AGV processing module: includes a reach truck AGV, wherein the forklift AGV is equipped with retractable forks (5), and a second cargo status detection sensor (6) is installed on the forks (5) to monitor the tilt and load status of the cargo in real time; Four-way automated storage and retrieval system (AS / RS) module: includes an upper storage area and a lower picking area. The storage area is equipped with four-way vehicles for horizontal and vertical transport of goods. The picking area has a loading port that connects to the shipping channel. Collaborative Control Module: The top-mounted lurking AGV transfer module, the forklift AGV processing module, and the four-way vehicles in the four-way vehicle vertical warehouse module are respectively connected to the collaborative control module to establish a two-way communication system and realize real-time synchronization of task instructions. The collaborative control module has a built-in dynamic path algorithm, which is used to adjust the transfer route of the lurking AGV, the operation sequence of the forklift AGV, and the operation path of the four-way vehicles in the four-way vehicle vertical warehouse module in real time according to the inventory status of the four-way vehicle vertical warehouse module, the AGV task queue, and the operation status of the downstream processing area. The WMS system and digital twin integration module includes a WMS system and a digital twin platform. The WMS system connects with AGVs, forklift AGVs, and four-way vehicle signals to achieve refined management of the entire warehousing process. The digital twin platform is used to build a virtual model that is completely mapped to the physical warehousing system, synchronize the operation data of each module in real time, realize the visual monitoring of the entire warehousing process, optimize AGV path planning and automated warehouse layout by simulating different operating scenarios, and perform predictive maintenance on equipment operating status.

2. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 1, characterized in that: An anti-slip buffer pad is provided above the lifting platform (2), and the first cargo status detection sensor (3) is installed on the anti-slip buffer pad.

3. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 1, characterized in that: The extension range of the forks (5) is 1-1.2m.

4. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 1, characterized in that: The storage area and sorting area are respectively equipped with shelf units. The shelf units are equipped with modular matrix units, longitudinal and transverse rail units, standard storage units and support connection units, and are equipped with safety and leveling components. The surface of the shelf units is coated with anti-static material.

5. The integrated AGV-forklift AGV-four-way vehicle-assisted warehouse system for paper mills as described in claim 1, characterized in that, The dynamic path algorithm in the collaborative control module adopts a path optimization model based on genetic algorithm.

6. The operating method of the integrated AGV-forklift AGV-four-way vehicle automated storage and retrieval system for paper mills according to any one of claims 1-5, characterized in that, Includes the following steps: Step S1: The lurking AGV receives the shipment instruction from the printing machine linkage line, drives under the material outlet of the linkage line, raises the lifting platform (2) to lift the goods, and completes the transfer including the pallet. Step S2: The lurking AGV transfers the goods to the downstream processing area through the upper-level instructions and sends an inbound instruction to the four-way vehicle-mounted warehouse module; Step S3: After the goods are processed in the back-end processing area, the goods are transferred to the high-bay racking area by a forklift AGV and an inbound instruction is sent to the four-way vehicle upright warehouse module; Step S4: After receiving the storage instruction from the lurking AGV or forklift AGV, the four-way vehicle vertical warehouse module opens the warehouse door. The collaborative control module begins to plan the storage path and sends the path instructions to the lurking AGV or forklift AGV. The lurking AGV or forklift AGV stores the goods in the upper storage area according to the path instructions. When there is a delivery requirement, the collaborative control module plans the delivery path. The four-way vehicle in the storage area transfers the goods from the upper storage area to the lower picking area according to the delivery path, and completes the delivery by connecting to the delivery channel through the bottom delivery port. Step S5: The WMS system and the digital twin fusion module synchronize data from all stages in real time to achieve inventory management, path optimization, and predictive maintenance of equipment.

7. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 6, characterized in that, In step S1, before lifting the goods, the lurking AGV first identifies the specifications and weight of the goods through a visual recognition and laser positioning system, and adjusts the load-bearing and transfer posture of the lifting platform (2) accordingly.

8. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 6, characterized in that, In step S3, the forklift AGV monitors the tilt and load-bearing status of the goods in real time during the transfer of goods to the high-level racking area. If any abnormality occurs, the operation is stopped immediately and feedback is sent to the WMS system and digital twin platform.

9. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills as described in claim 6, characterized in that, In step S4, the storage and retrieval of goods in the four-way vehicle vertical warehouse module follows the principle of "store first, then retrieval".

10. The integrated AGV-forklift AGV-four-way automated warehouse system for paper mills according to claim 6, characterized in that, In step S5, the digital twin platform optimizes the path planning of the lurking AGV and forklift AGV, as well as the layout of the storage and sorting areas of the automated warehouse, every hour by simulating different operating scenarios.

Images