An automated storage and retrieval system for storing thin film rolls

Abstract

This invention belongs to the field of roll material storage technology, specifically referring to an automated three-dimensional warehouse for storing film rolls. It includes a closed three-dimensional storage cabinet, a multi-layer matrix storage rack, a servo-driven stacker crane, a flexible clamping and picking mechanism, a constant temperature and humidity dust removal and purification mechanism, an intelligent sensing and monitoring mechanism, and a storage control module. This invention solves the problem of roll material easily rolling, deforming, and becoming unusable during storage by using split-type arc-shaped support rollers and a limiting structure; it eliminates defects such as scratches and low yield rates caused by manual handling by relying on the servo stacker crane and flexible clamping mechanism; it improves the dust and moisture defects of open storage by using a sealed cabinet equipped with a temperature and humidity dust removal system; it enhances storage utilization and operational efficiency through multi-layer matrix storage and intelligent scheduling; and it adapts to multiple specifications of roll materials using an adjustable support structure and an IoT control module, achieving accurate inventory and full traceability of materials.

Description

Technical Field

[0001] This invention belongs to the field of roll material storage technology, specifically referring to an automated three-dimensional warehouse for storing film rolls. Background Technology

[0002] Film rolls, including PET, PE, BOPP, EVA, optical films, and packaging films, are core raw materials and finished products in the photovoltaic, packaging, electronics, and printing industries. They possess unique properties such as flexibility and easy deformation, susceptibility to scratches, moisture and dust sensitivity, cylindrical and irregular shapes, and large weight ranges. Currently, the industry commonly uses traditional flat shelving combined with manual forklift handling for film roll storage, which suffers from inherent defects in the transmission and load-bearing structures of warehousing equipment.

[0003] Currently, the industry generally uses traditional flat racks combined with manual forklift handling for film rolls. However, the transmission and load-bearing structures of these storage equipment have many inherent defects. Traditional warehousing methods and equipment suffer from the following core technical problems: First, traditional flat racks often use a flat lifting load-bearing structure, which cannot adapt to the irregular shape of cylindrical rolls. The rolls are prone to rolling and tilting during storage, and long-term storage can lead to end-face compression deformation and loosening of the film layer, resulting in product scrap. Second, manual forklift handling has low precision, and the film surface is easily scratched and damaged during operation, compromising the performance of optical films and precision packaging films, making it difficult to guarantee yield. Third, traditional warehousing is an open storage structure without a constant temperature and humidity control system or a dust and moisture prevention system. Film rolls are highly susceptible to moisture absorption, oxidation, and dust absorption, especially photovoltaic films. Electron optical films have extremely high requirements for the storage environment; moisture and dust accumulation will directly affect the accuracy of subsequent processing. Fourth, traditional warehousing space utilization is low, and flat stacking storage methods cannot achieve three-dimensional high-density storage. Moreover, manual access operations are inefficient and cannot meet the needs of assembly line production and supply. Fifth, the weight range of roll materials is extremely wide, with lightweight film rolls weighing less than 50kg and heavy industrial rolls reaching several tons. Traditional shelving has a single load-bearing structure and cannot stably support roll materials of different weights, resulting in poor versatility. Sixth, manual inventory and access are prone to counting errors, incorrect or missed retrieval, and low accuracy in warehouse material management, making it impossible to achieve intelligent traceability management of roll materials. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention provides an automated three-dimensional warehouse for storing film rolls, which solves the technical problems of poor adaptability of existing film roll storage equipment, easy damage to the rolls, poor storage environment, low space utilization, insufficient automation and low material management accuracy.

[0005] To address the problem that traditional flat shelving cannot accommodate the storage of cylindrical roll materials and easily causes deformation and loosening of the rolls, this invention adopts an arc-shaped adaptive load-bearing positioning method, setting up a split arc-shaped load-bearing roller group and a limiting anti-roll structure. This achieves the technical effect of fully covering and flexibly supporting cylindrical film roll materials and storing them at fixed points, effectively preventing the problems of roll material rolling, tilting, and compression deformation. To solve the problem that manual forklift handling is prone to scratching and bumping the film roll materials, this invention creatively proposes a servo-driven precise alignment automated storage and retrieval structure. Through the coordinated motion principle of the aisle stacker crane and the flexible clamping and picking mechanism, it achieves the technical effect of unmanned precise storage and retrieval and zero-contact scratching.

[0006] The technical solution adopted in this invention is as follows: An automated three-dimensional warehouse for storing film rolls includes a closed three-dimensional storage cabinet, a multi-layer matrix storage rack, a servo aisle stacker crane, a flexible gripping and picking mechanism, a constant temperature and humidity dust removal and purification mechanism, an intelligent sensing and monitoring mechanism, and a storage control module. The multi-layer matrix storage rack is evenly arranged inside the closed three-dimensional storage cabinet. The servo aisle stacker crane is slidably positioned in the central aisle position inside the closed three-dimensional storage cabinet. The flexible gripping and picking mechanism is fixedly installed on the lifting end of the servo aisle stacker crane. The constant temperature and humidity dust removal and purification mechanism is embedded in the top and side walls of the closed three-dimensional storage cabinet. The intelligent sensing and monitoring mechanism is evenly distributed in each storage compartment of the multi-layer matrix storage rack. The storage control module is fixedly installed in the control cabinet outside the closed three-dimensional storage cabinet.

[0007] The multi-layer matrix storage rack includes vertical support columns, horizontal load-bearing beams, layered load-bearing roller assemblies, and end limiting baffles. The vertical support columns are symmetrically arrayed inside the enclosed three-dimensional storage cabinet. The horizontal load-bearing beams are fixedly connected between adjacent vertical support columns. The layered load-bearing roller assemblies are detachably installed above the horizontal load-bearing beams. The end limiting baffles are fixed at both ends of the layered load-bearing roller assemblies.

[0008] Furthermore, the layered load-bearing idler assembly adopts an adaptive centering flexible load-bearing structure, including a detachable fixed base, two sets of adjustable arc-shaped idlers, a high-elasticity anti-slip buffer layer, a double-lead counter-tensioning adjustment screw, a roll material centering auxiliary structure, and a static anti-indentation support structure. The fixed base is snapped and fixed to the transverse load-bearing beam. The double-lead counter-tensioning adjustment screw is horizontally inserted into the center position inside the fixed base. The two sets of adjustable arc-shaped idlers are symmetrically slidably assembled above the fixed base via bottom slides. The bottom slides of the two sets of adjustable arc-shaped idlers are respectively connected to the double-lead counter-tensioning adjustment screw. The rod is threaded at both ends, and a lead servo motor is installed on the side wall of the fixed base. The output end of the lead servo motor is connected to the double lead counter-pulling spacing adjustment screw, so as to realize the synchronous centering and opening and closing of the two side rollers driven by a single screw, eliminating the problems of unilateral offset and centering deviation. The high-elasticity anti-slip buffer pad fully covers and adheres to the outer arc surface of the adjustable arc roller. The pad is made of microporous silicone flexible material, which has both high anti-slip properties and deformation buffering capacity. The roll material centering auxiliary structure is set on the inner side of the two sets of adjustable arc rollers, and the static anti-indentation support structure is evenly distributed on the bearing arc surface of the adjustable arc roller.

[0009] This optimized structure abandons the traditional single-roller fixed rigid support structure and adopts a bidirectional synchronous centering adjustment, full-area flexible buffer and adaptive centering load-bearing integrated structure. Through the synchronous transmission of the forward and reverse teeth of the dual-lead pull-pitch adjustment screw, the two sets of adjustable arc-shaped rollers always keep the center aligned during the adjustment process, without the need for manual calibration and alignment. It can accurately adapt to the center load-bearing benchmark of film rolls of different diameters (300mm-1200mm). With the adjustable arc-shaped roller's fully covered flexible pad and multi-point anti-indentation support structure, the traditional line contact load-bearing is optimized to arc-surface contact load-bearing, which greatly disperses the load-bearing stress at the bottom of the roll and completely solves the problems of local indentation of heavy rolls, extrusion indentation of ultra-thin film rolls and long-term loosening and deformation.

[0010] Furthermore, the roll material centering auxiliary structure includes a low-position limiting edge and an adaptive micro-top spring sheet group. The low-position limiting edge is symmetrically arranged at both ends of the adjustable arc-shaped idler roller to limit the axial displacement of the roll material. The adaptive micro-top spring sheet group is uniformly embedded in the inner side of the arc surface of the adjustable arc-shaped idler roller. When the roll material is dropped, the adaptive micro-top spring sheet group adaptively conforms to the slight arc error of the outer wall of the roll material, automatically corrects the eccentricity of the roll material storage, and ensures that each drop is in the central bearing position, preventing the roll material from being skewed or subjected to force on one side.

[0011] Furthermore, the static anti-indentation support structure includes a uniformly arrayed array of flexible buffer bumps and pressure-relieving grooves. The flexible buffer bumps are integrally foamed with gradient density microporous silicone and arranged in an array on the bearing arc surface of the high-elasticity anti-slip buffer pad. The surface of the flexible buffer bumps is dense and anti-slip, while the inner layer is porous and buffering, possessing flexible deformation recovery and uniform pressure distribution characteristics. Interlaced pressure-relieving grooves are opened between adjacent flexible buffer bumps. The grooves adopt a streamlined structure that is deep in the middle and shallow on both sides, penetrating the inner and outer sides of the pad without dead angles. This structure abandons the traditional one-piece solid soft pad support method and optimizes the traditional whole-surface pressure support into a multi-point independent suspension support and a full-area pressure relief and flow-guiding composite structure. When the roll material is laid still, each flexible buffer protrusion can undergo differentiated micro-adaptive deformation according to the curvature of the roll material's outer wall and the magnitude of local pressure, automatically filling the tiny gap between the roll material and the idler roller, achieving uniform adhesion and support throughout the entire area, and completely eliminating local stress concentration; at the same time, the through-type flow-guiding and pressure-relieving groove can discharge the sealed air on the bonding surface in real time, eliminating problems such as roll material adhesion, suction marks, and sticking caused by negative pressure adsorption, and can also quickly guide condensed water vapor and accumulated dust, avoiding defects such as film watermarks, local oxidation, and dust indentations caused by water vapor retention; in addition, the component adopts a modular quick-installation structure, which can be disassembled as a whole and maintained and replaced individually, without the need to disassemble the entire rack, greatly reducing equipment operation and maintenance costs.

[0012] As a further preferred embodiment of the present invention, the servo-driven aisle stacker crane includes a ground sliding track, a frame body, a servo lifting module, a horizontal walking servo motor, and a lifting winch unit. The ground sliding track is fixedly laid on the floor of the aisle inside the enclosed three-dimensional storage cabinet. The bottom of the frame body is slidably engaged with the ground sliding track. The horizontal walking servo motor is located on the side wall at the bottom of the frame body and is connected to the ground sliding track. The servo lifting module is vertically slidably installed inside the frame body. The lifting winch unit is located at the top of the frame body, and the winch retraction end of the lifting winch unit is connected to the servo lifting module, thereby realizing precise horizontal walking and precise vertical lifting of the stacker crane and ensuring storage and retrieval positioning accuracy.

[0013] As a further preferred embodiment of the present invention, the flexible clamping and picking mechanism adopts a high-precision bilateral synchronous transmission floating clamping structure, including two sets of dual synchronous telescopic drive components, a floating clamping bracket, a flexible anti-slip pad, a synchronous transmission module, and a radial angle floating compensation structure. The two sets of dual synchronous telescopic drive components are symmetrically fixed on both sides of the lifting end of the servo lifting module. The synchronous transmission module is mounted between the two sets of dual synchronous telescopic drive components to achieve bilateral mechanical synchronous telescopic transmission, completely eliminating the problems of unilateral offset and inconsistent stroke in traditional single-drive structures. The floating clamping bracket is movably hinged to the telescopic end of the dual synchronous telescopic drive components through the radial angle floating compensation structure. The flexible anti-slip pad is fully covered and fitted onto the inner clamping surface of the floating clamping bracket. The flexible anti-slip pad has an internal array of embedded multi-point pressure sensing components to achieve real-time detection of clamping pressure across the entire range.

[0014] Furthermore, the dual synchronous telescopic drive assembly includes two sets of precision servo electric cylinders, a linear guide rail, and a displacement reading grating. The two sets of precision servo electric cylinders are respectively fixed to the side of the servo lifting module. The linear guide rail is arranged outside the precision servo electric cylinders to ensure the straightness of the telescopic movement. The displacement reading grating is located on the side of the linear guide rail to provide real-time feedback on the telescopic stroke position on both sides.

[0015] Furthermore, the synchronous transmission module includes a bidirectional transmission screw, a synchronous worm gear reducer, and a centrally located servo synchronous motor. The centrally located servo synchronous motor is fixed in the middle of the servo lifting module. The synchronous worm gear reducer is rigidly connected to the output end of the centrally located servo synchronous motor. The bidirectional transmission screw is horizontally inserted through the worm gear reducer. Both ends of the bidirectional transmission screw are respectively engaged with precision servo electric cylinders on both sides to form a mechanically forced synchronous transmission structure. This structure can achieve millimeter-level synchronous extension and retraction of the double-sided clamping structure, eliminate left and right stroke deviations, and ensure precise alignment between the clamping center and the center of the roll material.

[0016] Furthermore, the radial angle floating compensation structure includes a buffer spring assembly and a universal hinge seat. The universal hinge seat is located between the output end of the dual synchronous telescopic drive assembly and the floating clamping bracket. The buffer spring assembly is arranged around the outer periphery of the universal hinge seat, which can realize small radial floating of the clamping bracket and multi-angle adaptive fine adjustment. It can automatically adapt to the roundness error of the outer wall of the film roll and the slight eccentricity deviation during storage, and completely avoid the problems of local stress concentration, roll indentation and film deformation caused by rigid clamping.

[0017] This structural optimization abandons the traditional single-cylinder cantilever transmission and pure rigid clamping structure, and adopts a composite transmission clamping structure of "mechanical forced synchronous transmission, full-range pressure detection and multi-dimensional floating adaptive compensation". It solves the technical defects of the traditional structure from the root of transmission, such as uneven force, clamping skew, poor alignment accuracy and easy damage to the roll material.

[0018] The dual-sided synchronous lead screw and worm gear mechanical linkage ensures complete synchronization of feed on both sides during the picking of heavy and large-span film rolls, resulting in stable clamping posture without deviation. The multi-dimensional floating compensation structure can adapt to the shape error and placement deviation of the roll, eliminating hard bumps and scratches. With the array of multi-point pressure sensing components, the control system can collect pressure data across the entire clamping range in real time and dynamically adjust the extension stroke and clamping pre-tightening force in a closed loop. It adaptively matches clamping parameters for different types of materials such as ultra-thin flexible films, high-precision optical films, and thick industrial rolls, eliminating problems such as roll end face concavity, film layer compression and loosening, and optical surface damage caused by excessive clamping, while avoiding the risks of slippage, falling, shaking and displacement caused by excessively loose clamping. It comprehensively improves the safety, accuracy and versatility of automated roll picking, fully meeting the stringent operational requirements of non-destructive storage and retrieval of high-precision film rolls.

[0019] As a further preferred embodiment of the present invention, the constant temperature and humidity dust removal and purification mechanism includes a constant temperature regulating component 1, a humidity regulating component, a negative ion dust removal filter, and a circulating air duct. The circulating air duct is installed inside the enclosed three-dimensional storage cabinet. The constant temperature regulating component and the humidity regulating component are embedded in the middle section of the circulating air duct. The negative ion dust removal filter is detachably installed at the air inlet of the circulating air duct, so as to realize the air circulation and purification inside the cabinet, maintain constant temperature and humidity, and remove dust and impurities.

[0020] As a further preferred embodiment of the present invention, the intelligent sensing and monitoring mechanism includes a temperature and humidity sensor, a pressure and load sensor, and a displacement monitoring sensor. The temperature and humidity sensor and the displacement monitoring sensor are fixed on the side wall of the vertical support column of the corresponding storage compartment. The pressure and load sensor is embedded in the bottom of the layered load-bearing roller assembly to monitor the storage environment parameters, the storage status of the roll material, and the load-bearing pressure in real time, so as to realize real-time early warning of abnormalities.

[0021] As a further preferred embodiment of the present invention, the warehouse control module adopts an STM32F407 microcontroller. The warehouse control module is electrically connected to the servo aisle stacker crane, the flexible clamping and picking mechanism, the constant temperature and humidity dust removal and purification mechanism, and the intelligent sensing and monitoring mechanism. The warehouse control module collects the operating data and sensor monitoring data of each mechanism, and coordinates the start and stop, operating parameters and operation process of each mechanism to realize the automated and intelligent operation of the warehouse.

[0022] The advantages of the automated storage and retrieval system (AS / RS) for storing film rolls provided by this solution are as follows: (1) In view of the problems that traditional shelves cannot adapt to cylindrical rolls, are prone to deformation and loosening, and are prone to indentation, this invention innovatively adopts a bidirectional split self-adaptive centering flexible bearing roller structure. Through the synchronous centering adjustment of the dual lead screw, it can adapt to rolls of different diameters and specifications for precise centering and bearing. At the same time, it adopts arc-shaped full-area flexible surface contact support to replace the traditional line contact support. Combined with anti-indentation and pressure relief diversion structure, it completely solves the defects of bottom indentation, local stress concentration, eccentricity and skewing, and loosening and deformation of rolls, and realizes non-destructive static storage of all types of film rolls. (2) In view of the problem that manual forklifts are prone to scratching and bumping the roll material, the present invention adopts a servo precision positioning unmanned storage and retrieval method, combined with a flexible clamping and picking structure, to achieve zero manual intervention and zero hard contact storage and retrieval, completely avoid scratches and bumps on the film surface, and ensure the product quality of precision film roll material. (3) In view of the problem that traditional open storage has poor dust and moisture protection effect, the present invention adopts a closed cabinet integrated constant temperature and humidity dust removal structure to regulate the storage environment in real time, keep the warehouse dust-free, constant temperature and humidity, effectively prevent the film roll from getting damp and oxidized, and dust accumulation and pollution, and adapt to the high standard storage requirements of photovoltaic and electronic grade precision films. (4) In view of the problem of low utilization rate of traditional flat warehouse space, the present invention adopts a multi-layer matrix three-dimensional warehouse layout. Compared with traditional flat shelves, the utilization rate of warehouse space is increased by more than 60%, which can realize high-density centralized storage of large quantities of roll materials. (5) In view of the problem of poor adaptability of traditional equipment, the present invention adopts a modular adjustable load-bearing structure, which can flexibly adjust the load-bearing spacing and load-bearing strength according to the diameter, width and weight of the roll material, and is suitable for all kinds of film roll materials of different weights and specifications from 50kg to 5t, making the equipment extremely versatile. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of an automated three-dimensional warehouse for storing film rolls proposed in this invention; Figure 2 This is a diagram of the internal structure of a closed, automated storage unit. Figure 3 This is a schematic diagram of a multi-layer matrix storage rack structure; Figure 4 This is a schematic diagram of the structure of a layered load-bearing idler assembly; Figure 5 This is a schematic diagram of the adjustable arc-shaped idler roller. Figure 6 This is a structural schematic diagram of a servo-driven stacker crane. Figure 7 This is a schematic diagram of the flexible clamping and picking mechanism. Figure 8 A schematic diagram of the dual synchronous telescopic drive assembly; Figure 9 This is a schematic diagram of a radial angle floating compensation structure.

[0024] Among them, 1. Enclosed three-dimensional storage cabinet, 2. Multi-layer matrix storage rack, 3. Servo aisle stacker crane, 4. Flexible clamping and picking mechanism, 5. Constant temperature and humidity dust removal and purification mechanism, 6. Intelligent sensing and monitoring mechanism, 7. Storage control module, 201. Vertical support column, 202. Horizontal load-bearing beam, 203. Layered load-bearing roller assembly, 204. End limit baffle, 205. Detachable fixed base, 206. Adjustable arc-shaped roller, 207. High-elasticity anti-slip buffer pad, 208. Dual-lead pull-out spacing adjustment screw, 209. Roll material centering auxiliary structure, 210. Low-position limit guard, 211. Adaptive micro-top spring assembly, 212. Static anti-indentation support structure, 213. Flexible buffer protrusion, 214. Flow guide and pressure relief groove, 215. Lead servo motor, 301. Ground sliding track, 3 02. Main frame; 303. Servo lifting module; 304. Horizontal travel servo motor; 305. Lifting winch unit; 401. Dual synchronous telescopic drive assembly; 402. Precision servo electric cylinder; 403. Linear guide rail; 404. Displacement reading grating; 405. Synchronous transmission module; 406. Bidirectional transmission screw; 407. Synchronous worm gear reducer; 408. Centered servo synchronous motor; 409. Floating clamping bracket; 410. Radial angle floating compensation structure; 411. Universal hinge seat; 412. Buffer spring assembly; 413. Flexible anti-slip pad; 501. Constant temperature control assembly; 502. Humidity control assembly; 503. Negative ion dust removal filter; 504. Circulating air duct; 601. Temperature and humidity sensor; 602. Pressure load sensor; 603. Displacement monitoring sensor.

[0025] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Detailed Implementation

[0026] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0027] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0028] like Figures 1-9 As shown, this invention provides an automated three-dimensional warehouse for storing film rolls. It includes a closed three-dimensional storage cabinet 1, multi-layer matrix storage racks 2, a servo aisle stacker crane 3, a flexible gripping and picking mechanism 4, a constant temperature and humidity dust removal and purification mechanism 5, an intelligent sensing and monitoring mechanism 6, and a storage control module 7. The multi-layer matrix storage racks 2 are evenly arranged inside the closed three-dimensional storage cabinet 1. The servo aisle stacker crane 3 is slidably positioned in the central aisle position inside the closed three-dimensional storage cabinet 1. The flexible gripping and picking mechanism 4 is fixedly installed on the lifting end of the servo aisle stacker crane 3. The constant temperature and humidity dust removal and purification mechanism 5 is embedded in the top and side walls of the closed three-dimensional storage cabinet 1. The intelligent sensing and monitoring mechanism 6 is evenly distributed in each storage compartment of the multi-layer matrix storage racks 2. The storage control module 7 is fixedly installed in the control cabinet outside the closed three-dimensional storage cabinet 1.

[0029] The multi-layer matrix storage rack 2 includes vertical support columns 201, horizontal load-bearing beams 202, layered load-bearing roller assemblies 203, and end limiting baffles 204. The vertical support columns 201 are symmetrically arrayed inside the enclosed three-dimensional storage cabinet 1. The horizontal load-bearing beams 202 are fixedly connected between adjacent vertical support columns 201. The layered load-bearing roller assemblies 203 are detachably installed above the horizontal load-bearing beams 202. The end limiting baffles 204 are fixedly installed at both ends of the layered load-bearing roller assemblies 203. The layered load-bearing roller assemblies 203 adopt an adaptive centering flexible bearing system. The load-bearing structure includes a detachable fixed base, two sets of adjustable arc-shaped idlers 206, a high-elasticity anti-slip buffer layer 207, a double-lead counter-pull spacing adjustment screw 208, a roll material centering auxiliary structure 209, and a static anti-indentation support structure 212. The fixed base is snapped and fixed to the transverse load-bearing beam 202. The double-lead counter-pull spacing adjustment screw 208 is horizontally inserted into the center of the fixed base. The two sets of adjustable arc-shaped idlers 206 are symmetrically slidably mounted on the fixed base via bottom slides. The bottom slides of the two sets of adjustable arc-shaped idlers 206 are respectively connected to the double-lead counter-pull spacing adjustment screw. The rod 208 is threaded at both ends. A lead servo motor 215 is installed on the side wall of the fixed base. The output end of the lead servo motor 215 is connected to the double lead counter-pulling spacing adjustment screw 208. A high-elasticity anti-slip buffer layer 207 fully covers and adheres to the outer arc surface of the adjustable arc roller 206. The roll material centering auxiliary structure 209 is located inside the two sets of adjustable arc rollers 206. The static anti-indentation support structure 212 is evenly distributed on the bearing arc surface of the adjustable arc roller 206. The roll material centering auxiliary structure 209 includes a low-position limiting edge 210 and an adaptive micro-top spring sheet group 21. 1. Low-position limiting guards 210 are symmetrically arranged at both ends of the adjustable arc-shaped idler roller 206, and adaptive micro-top elastic sheet groups 211 are uniformly embedded in the inner side of the arc surface of the adjustable arc-shaped idler roller 206; the static anti-indentation support structure 212 includes a uniform array of flexible buffer bumps 213 and a flow-guiding and pressure-relieving groove 214. The flexible buffer bumps 213 are integrally foamed with gradient density microporous silicone and arranged in an array on the bearing arc surface of the high-elasticity anti-slip buffer pad layer 207; staggered flow-guiding and pressure-relieving grooves 214 are opened between adjacent flexible buffer bumps 213, and the grooves adopt a streamlined structure that is deep in the middle and shallow on both sides.

[0030] The servo-driven stacker crane 3 includes a ground sliding track 301, a frame body 302, a servo lifting module 303, a horizontal walking servo motor 304, and a lifting winch unit 305. The ground sliding track 301 is fixedly laid on the floor of the internal aisle of the enclosed three-dimensional storage cabinet 1. The bottom of the frame body 302 is slidably engaged with the ground sliding track 301. The horizontal walking servo motor 304 is located on the side wall at the bottom of the frame body 302 and is connected to the ground sliding track 301. The servo lifting module 303 is vertically slidably installed inside the frame body 302. The lifting winch unit 305 is located at the top of the frame body 302, and the winch retraction end of the lifting winch unit 305 is connected to the servo lifting module 303.

[0031] The flexible clamping and picking mechanism 4 adopts a high-precision double-sided synchronous transmission floating clamping structure, including two sets of dual synchronous telescopic drive components 401, a floating clamping bracket 409, a flexible anti-slip pad 413, a synchronous transmission module 405, and a radial angle floating compensation structure 410. The two sets of dual synchronous telescopic drive components 401 are symmetrically fixed on both sides of the lifting end of the servo lifting module 303. The synchronous transmission module 405 is mounted between the two sets of dual synchronous telescopic drive components 401, completely eliminating the problems of unilateral offset and inconsistent stroke in the traditional single-drive structure. The floating clamping bracket 409 is movably hinged to the telescopic end of the dual synchronous telescopic drive component 401 through the radial angle floating compensation structure 410. The flexible anti-slip pad 413 is fully covered and fitted on the inner clamping surface of the floating clamping bracket 409. The flexible anti-slip pad 413 has a multi-point pressure sensing component embedded in its internal array. The dual synchronous telescopic drive component 401 includes two sets of precision servo electric cylinders 402, a linear guide rail 403, and a displacement reading grating 404. Precision servo electric cylinders 402 are fixed to the side of the servo lifting module 303. A linear guide rail 403 is arranged outside the precision servo electric cylinders 402, and a displacement reading grating 404 is located on the side of the linear guide rail 403. The synchronous transmission module 405 includes a bidirectional transmission screw 406, a synchronous worm gear reducer 407, and a centrally located servo synchronous motor 408. The centrally located servo synchronous motor 408 is fixed in the middle of the servo lifting module 303. The synchronous worm gear reducer 407 and the centrally located servo synchronous motor 408... The output end of the synchronous motor 408 is rigidly connected, and the bidirectional transmission screw 406 is horizontally installed through the worm gear reducer. The two ends of the bidirectional transmission screw 406 are respectively engaged and linked with the precision servo electric cylinders 402 on both sides. The radial angle floating compensation structure 410 includes a buffer spring group 412 and a universal hinge seat 411. The universal hinge seat 411 is located between the output end of the dual synchronous telescopic drive assembly 401 and the floating clamping bracket 409. The buffer spring group 412 is arranged around the outer periphery of the universal hinge seat 411.

[0032] The constant temperature and humidity dust removal and purification mechanism 5 includes a constant temperature regulating component 501, a humidity regulating component 502, a negative ion dust removal filter 503, and a circulating air duct 504. The circulating air duct 504 is installed inside the enclosed three-dimensional storage cabinet 1. The constant temperature regulating component 501 and the humidity regulating component 502 are embedded in the middle section of the circulating air duct 504. The negative ion dust removal filter 503 is detachably installed at the air inlet end of the circulating air duct 504.

[0033] The intelligent sensing and monitoring mechanism 6 includes a temperature and humidity sensor 601, a pressure and load sensor 602, and a displacement monitoring sensor 603. The temperature and humidity sensor 601 and the displacement monitoring sensor 603 are fixed on the side wall of the vertical support column 201 of the corresponding storage compartment, and the pressure and load sensor 602 is embedded in the bottom of the layered load-bearing roller assembly 203.

[0034] The specific work process is as follows: Step 1: Warehouse Initialization and Environmental Pretreatment. After the equipment is powered on, the warehouse control module 7 initiates a system self-test, checking the operating status of each servo mechanism, sensor component, and purification mechanism. After confirming that the equipment is fault-free, the constant temperature and humidity dust removal and purification mechanism 5 is activated. The internal air circulation of the cabinet is achieved through the circulating air duct 504, the negative ion dust removal filter 503 removes dust and impurities in the warehouse, and the constant temperature adjustment component 501 and humidity adjustment component 502 adjust the temperature and humidity in the warehouse to the standard range for film roll storage (temperature 18-25℃, humidity 40%-60%), completing the pretreatment of the warehouse environment. At the same time, the intelligent sensor monitoring mechanism 6 collects the environmental data in the warehouse in real time and uploads it to the control module to achieve dynamic voltage stabilization and control.

[0035] Step 2: Roll Material Receiving Identification and Parameter Adaptation. After the film rolls to be stored are transported to the warehouse receiving station, the specifications, material, weight, and batch information of the rolls are read by a barcode scanning camera and transmitted to the warehouse control module 7. The warehouse control module 7 automatically drives the spacing adjustment screw to operate according to the roll diameter and weight parameters. The lead servo motor 215 drives the double lead counter-pull spacing adjustment screw 208 to simultaneously adjust the spacing of the adjustable arc-shaped rollers 206 and automatically center and align them to adapt to the roll size. At the same time, it matches the shelf load warning threshold according to the roll weight to complete the parameter adaptation before receiving.

[0036] Step 3: Automated Pick-up and Storage. The warehouse control module 7 schedules the servo-driven stacker crane 3 to start operation. The horizontal travel servo motor 304 drives the main frame 302 to precisely move along the ground sliding track 301 to the storage station. The lifting winch unit 305, in conjunction with the servo lifting module 303, adjusts the height to align the flexible clamping and picking mechanism 4 with the center of the roll material. Subsequently, the dual synchronous telescopic drive assembly 401, under the mechanical linkage of the synchronous transmission module 405, synchronously feeds, driving the floating clamping supports 409 on both sides to close smoothly, and the flexible anti-slip pads 413 are affixed. The outer wall of the coil material is closed, and the pressure sensing component provides real-time feedback on the clamping pressure. The control module adaptively adjusts the clamping force to ensure stable clamping without squeezing the coil material. After picking up, the servo-driven stacker crane 3 transports the coil material to the designated empty storage space. After precise alignment, the coil material is smoothly placed onto the adjustable arc-shaped idler roller 206. The coil material centering auxiliary structure 209 automatically corrects storage deviations, and the end limit baffle 204 achieves bidirectional limit to prevent deviation and rolling. Relying on the anti-indentation support structure, it achieves non-destructive and stable load bearing, completing the automatic warehousing process. Step 4: Real-time monitoring and dynamic control of the warehouse. After the roll material is stored, the pressure load sensor 602 monitors the load-bearing pressure of the warehouse in real time, the displacement monitoring sensor 603 monitors whether the storage position of the roll material has shifted, and the temperature and humidity sensor 601 continuously monitors the environmental parameters inside the warehouse. If abnormal situations such as roll material eccentric displacement, overload, excessive temperature and humidity, or dust accumulation occur, the control module immediately triggers an audible and visual alarm and automatically adjusts the purification and temperature and humidity control mechanisms, while simultaneously recording abnormal data to achieve 24-hour unattended dynamic monitoring of the warehouse status. At the same time, the system automatically enters the roll material storage location, entry time, and batch information to establish a material storage file.

[0037] Step 5: Automated Outbound and Inventory Operations. Upon receiving the outbound instruction, the warehouse control module 7 accurately locates the target roll material storage location based on the material ledger, and dispatches the servo-driven stacker crane 3 and the flexible clamping and picking mechanism 4 to complete the automatic picking and conveying of the roll material out of the warehouse. During the outbound process, the barcode scanning mechanism verifies the material information a second time to avoid incorrect picking. During daily inventory checks, the system automatically dispatches equipment to traverse all storage locations, combines sensor data and barcode scanning data to complete the automatic inventory check, and generates an inventory report. No manual intervention is required, ensuring the accuracy of material management.

[0038] The above is the specific workflow of this invention. This step can be repeated next time it is used.

[0039] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0040] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention.

[0041] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. An automated three-dimensional warehouse for storing film rolls, characterized in that: The system includes a closed three-dimensional storage cabinet (1), a multi-layer matrix storage rack (2), a servo aisle stacker crane (3), a flexible clamping and picking mechanism (4), a constant temperature and humidity dust removal and purification mechanism (5), an intelligent sensing and monitoring mechanism (6), and a storage control module (7). The multi-layer matrix storage rack (2) is evenly arranged inside the closed three-dimensional storage cabinet (1). The servo aisle stacker crane (3) is slidably located in the central aisle position inside the closed three-dimensional storage cabinet (1). The flexible clamping and picking mechanism (4) is fixedly installed on the lifting end of the servo aisle stacker crane (3). The constant temperature and humidity dust removal and purification mechanism (5) is embedded in the top and side walls of the closed three-dimensional storage cabinet (1). The intelligent sensing and monitoring mechanism (6) is evenly arranged in each storage compartment of the multi-layer matrix storage rack (2). The storage control module (7) is fixedly installed in the control cabinet outside the closed three-dimensional storage cabinet (1).

2. The automated three-dimensional warehouse for storing film rolls according to claim 1, characterized in that: The multi-layer matrix storage rack (2) includes vertical support columns (201), horizontal load-bearing beams (202), layered load-bearing roller assemblies (203), and end limiting baffles (204). The vertical support columns (201) are symmetrically arranged in an array inside the enclosed three-dimensional storage cabinet (1). The horizontal load-bearing beams (202) are fixedly connected between adjacent vertical support columns (201). The layered load-bearing roller assemblies (203) are detachably installed above the horizontal load-bearing beams (202). The end limiting baffles (204) are fixedly installed at both ends of the layered load-bearing roller assemblies (203).

3. An automated three-dimensional warehouse for storing film rolls according to claim 2, characterized in that: The layered load-bearing roller assembly (203) adopts an adaptive centering flexible load-bearing structure, including a detachable fixed base, two sets of adjustable arc-shaped rollers (206), a high-elasticity anti-slip buffer layer (207), a double-lead counter-pulling spacing adjustment screw (208), a roll material centering auxiliary structure (209), and a static anti-indentation support structure (212). The fixed base is snapped and fixed on the transverse load-bearing beam (202). The double-lead counter-pulling spacing adjustment screw (208) is horizontally inserted into the center of the fixed base. The two sets of adjustable arc-shaped rollers (206) are symmetrically slidably mounted on the top of the fixed base via bottom slides. The bottom slides of the two sets of adjustable arc-shaped rollers (206) are threaded to both ends of the double-lead counter-pulling spacing adjustment screw (208). A lead servo is installed on the side wall of the fixed base. The output end of the motor (215) is connected to the double-lead counter-pulling gap adjustment screw (208). The high-elasticity anti-slip buffer pad (207) fully covers and adheres to the outer arc surface of the adjustable arc roller (206). The roll material centering auxiliary structure (209) is located on the inner side of the two sets of adjustable arc rollers (206). The static anti-indentation support structure (212) is evenly distributed on the bearing arc surface of the adjustable arc roller (206). The roll material centering auxiliary structure (209) includes a low-position limiting stop (210) and an adaptive micro-top spring sheet group (211). The low-position limiting stop (210) is symmetrically located at both ends of the adjustable arc roller (206). The adaptive micro-top spring sheet group (211) is evenly embedded in the inner side of the arc surface of the adjustable arc roller (206).

4. An automated three-dimensional warehouse for storing film rolls according to claim 3, characterized in that: The static anti-indentation support structure (212) includes a uniform array of flexible buffer bumps (213) and a flow-guiding and pressure-relieving groove (214). The flexible buffer bumps (213) are integrally foamed with gradient density microporous silicone and arranged in an array on the bearing arc surface of the high-elasticity anti-slip buffer pad (207). Interlaced flow-guiding and pressure-relieving grooves (214) are opened between adjacent flexible buffer bumps (213), and the grooves adopt a streamlined structure with a deep middle and shallow sides.

5. An automated three-dimensional warehouse for storing film rolls according to claim 4, characterized in that: The servo-driven stacker crane (3) includes a ground sliding track (301), a frame body (302), a servo lifting module (303), a horizontal walking servo motor (304), and a lifting winch unit (305). The ground sliding track (301) is fixedly laid on the floor of the inner aisle of the enclosed three-dimensional storage cabinet (1). The bottom of the frame body (302) is slidably engaged with the ground sliding track (301). The horizontal walking servo motor (304) is located on the side wall at the bottom of the frame body (302). The horizontal walking servo motor (304) is connected to the ground sliding track (301) in a transmission. The servo lifting module (303) is vertically slidably installed inside the frame body (302). The lifting winch unit (305) is located at the top of the frame body (302). The winch retraction end of the lifting winch unit (305) is connected to the servo lifting module (303).

6. An automated three-dimensional warehouse for storing film rolls according to claim 5, characterized in that: The flexible clamping and picking mechanism (4) adopts a high-precision bilateral synchronous transmission floating clamping structure, including two sets of dual synchronous telescopic drive components (401), a floating clamping bracket (409), a flexible anti-slip pad (413), a synchronous transmission module (405), and a radial angle floating compensation structure (410). The two sets of dual synchronous telescopic drive components (401) are symmetrically fixed on both sides of the lifting end of the servo lifting module (303). The synchronous transmission module (405) is mounted between the two sets of dual synchronous telescopic drive components (401). The floating clamping bracket (409) is movably hinged to the telescopic end of the dual synchronous telescopic drive component (401) through the radial angle floating compensation structure (410). The flexible anti-slip pad (413) is fully covered and fitted on the inner clamping surface of the floating clamping bracket (409). The flexible anti-slip pad (413) has a multi-point pressure sensing component embedded in its internal array.

7. An automated three-dimensional warehouse for storing film rolls according to claim 6, characterized in that: The dual synchronous telescopic drive assembly (401) includes two sets of precision servo electric cylinders (402), a linear guide rail (403), and a displacement reading grating (404). The two sets of precision servo electric cylinders (402) are respectively fixed to the side of the servo lifting module (303). The linear guide rail (403) is arranged outside the precision servo electric cylinders (402), and the displacement reading grating (404) is located on the side of the linear guide rail (403). The synchronous transmission module (405) includes bidirectional transmission. The system includes a lead screw (406), a synchronous worm gear reducer (407), and a central servo synchronous motor (408). The central servo synchronous motor (408) is fixed in the middle of the servo lifting module (303). The synchronous worm gear reducer (407) is rigidly connected to the output end of the central servo synchronous motor (408). The bidirectional transmission lead screw (406) is horizontally inserted through the worm gear reducer. Both ends of the bidirectional transmission lead screw (406) are respectively engaged and linked with the precision servo electric cylinders (402) on both sides.

8. An automated three-dimensional warehouse for storing film rolls according to claim 7, characterized in that: The radial angle floating compensation structure (410) includes a buffer spring assembly (412) and a universal hinge seat (411). The universal hinge seat (411) is located between the output end of the dual synchronous telescopic drive assembly (401) and the floating clamping bracket (409). The buffer spring assembly (412) is arranged around the outer periphery of the universal hinge seat (411).

9. An automated three-dimensional warehouse for storing film rolls according to claim 8, characterized in that: The constant temperature and humidity dust removal and purification mechanism (5) includes a constant temperature adjustment component (501), a humidity adjustment component (502), a negative ion dust removal filter (503), and a circulating air duct (504). The circulating air duct (504) is installed inside the closed three-dimensional storage cabinet (1). The constant temperature adjustment component (501) and the humidity adjustment component (502) are embedded in the middle section of the circulating air duct (504). The negative ion dust removal filter (503) is detachably installed at the air inlet of the circulating air duct (504).

10. An automated three-dimensional warehouse for storing film rolls according to claim 9, characterized in that: The intelligent sensing and monitoring mechanism (6) includes a temperature and humidity sensor (601), a pressure and load sensor (602), and a displacement monitoring sensor (603). The temperature and humidity sensor (601) and the displacement monitoring sensor (603) are fixed on the side wall of the vertical support column (201) of the corresponding storage compartment. The pressure and load sensor (602) is embedded in the bottom of the layered load-bearing roller assembly (203). The storage control module (7) is electrically connected to the servo aisle stacker (3), the flexible clamping and picking mechanism (4), the constant temperature and humidity dust removal and purification mechanism (5), and the intelligent sensing and monitoring mechanism (6).

Images