An automatic reorganization method, system, device and medium for a high rack spreader

Abstract

The application discloses an automatic recombination method, system, device and medium for a high rack scattered tray. The method comprises the following steps: obtaining a scattered tray list by screening real-time inventory data of the high rack through a WMS, and configuring an outbound task message to be sent to a dedicated persistent queue; obtaining a task identifier, a scattered tray identifier, a target empty tray identifier, a target tray station and a standard stacking type parameter by analyzing the outbound task message through a WCS, and generating a PLC execution instruction containing a stacker scheduling subtask and a manipulator scheduling subtask which are bound to the task identifier based on the analysis result; driving the tray stacking manipulator to grab goods from the scattered tray identifier position and stack the goods to the target empty tray identifier position according to the standard stacking type parameter at the target tray station through the PLC, and when it is determined that there are remaining goods after the scattered tray is grabbed, controlling the tray stacking manipulator to enter a full disassembly mode to move the remaining goods of the target scattered tray out. Through the technical scheme, the automatic recombination of the high rack scattered tray can be realized, and the utilization rate of the rack capacity is improved.

Description

Technical Field

[0001] This invention relates to the field of logistics automation and intelligent manufacturing technology, and in particular to an automatic reassembly method, system, equipment and medium for bulk pallets in high-bay warehouses. Background Technology

[0002] In industries such as tobacco and fast-moving consumer goods that use high-bay warehouses for storage management, in order to improve warehouse capacity utilization, it is usually necessary to automatically identify and reassemble loose pallets, that is, pallets with less than the standard full pallet size, or pallets of different batches or brands mixed together.

[0003] In existing technologies, semi-automatic reorganization methods based on manual intervention, warehouse control systems (WCS) scheduling methods based on fixed storage location rules, and inventory optimization methods based on simple palletization algorithms are commonly used to reorganize loose pallets in high-bay warehouses. However, in the semi-automatic reorganization method based on manual intervention, the warehouse management system (WMS) is only responsible for identifying the location of loose pallets and then issuing simple outbound instructions. After the loose pallets are taken out by the stacker crane, they are manually sorted, handled, and stacked at the palletizing station, and the remaining pallets are then manually carried back to the warehouse. This method heavily relies on manual operation, resulting in high labor costs and the risk of damage to goods due to manual handling. In the WCS scheduling method based on fixed storage location rules, the WCS usually only serves as an input-output execution channel, and can only perform pick-and-place operations according to the fixed storage location instructions issued by the WMS. Its scheduling logic is rigid, lacking the ability to verify the palletizing station and empty pallet resources in real time, and unable to dynamically adjust the behavior mode of the robotic arm according to the real-time status of the loose pallets. Inventory optimization methods based on simple stacker algorithms only stay at the business logic level and fail to build an end-to-end automated control chain from WMS to WCS, then to Programmable Logic Controller (PLC) and robotic arms. They cannot solve coordination problems at the equipment level, such as the motion coordination between the stacker crane and the robotic arm, the posture control during the robotic arm's grasping process, and the automatic handling of abnormal situations.

[0004] Therefore, when faced with the demand for high-frequency and fragmented pallet processing, how to solve the technical problems of low automation and poor equipment coordination in the pallet reorganization process, and realize the automatic reorganization of pallets in high-bay warehouses to improve warehouse capacity utilization, is an urgent problem to be solved. Summary of the Invention

[0005] This invention provides an automatic reorganization method, system, equipment, and medium for bulk pallets in elevated warehouses, which can solve the technical problems of low automation and poor equipment coordination in the bulk pallet reorganization process.

[0006] According to one aspect of the present invention, an automatic reassembly method for bulk pallets in a high-bay warehouse is provided. This method is applied to an automatic reassembly system for bulk pallets in a high-bay warehouse, which includes a Warehouse Management System (WMS), a message middleware, a Warehouse Control System (WCS), a Programmable Logic Controller (PLC), and a palletizing robot. The method includes: The warehouse management system (WMS) obtains real-time inventory data of the high-bay warehouse, filters the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configures the loose pallet list based on preset outbound rules to obtain outbound task messages. The outbound task message is sent to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware via WMS, so that the warehouse control system WCS can subscribe to and pull the outbound task message. The outbound task message is parsed by WCS to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier are generated. The stacker crane scheduling sub-task and the robot scheduling sub-task are written to the corresponding data block of the programmable logic controller (PLC) to obtain the PLC execution instructions. The PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to the standard pallet type parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. When it is determined that there are remaining goods after the target loose pallet is picked up, the palletizing robot is controlled to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reorganization task.

[0007] According to another aspect of the present invention, an automatic reassembly system for bulk pallets in a high-bay warehouse is provided, the system comprising: The Warehouse Management System (WMS) is used to acquire real-time inventory data of the high-bay warehouse, filter the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configure the loose pallet list based on preset outbound rules to obtain outbound task messages. WMS is used to send the outbound task message to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware, so that the warehouse control system WCS can subscribe to and pull the outbound task message. WCS is used to parse the outbound task message to obtain the task identifier, pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, stacker crane scheduling sub-tasks and robot scheduling sub-tasks bound to the task identifier are generated. The stacker crane scheduling sub-tasks and robot scheduling sub-tasks are written to the corresponding data blocks of the programmable logic controller (PLC) to obtain PLC execution instructions. The PLC is used to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier and place them on the target empty pallet corresponding to the target empty pallet identifier according to the standard pallet type parameters at the target palletizing station. When it is determined that there are remaining goods after the target loose pallet is picked up, the PLC controls the palletizing robot to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reorganization task.

[0008] According to another aspect of the present invention, an electronic device is provided, the electronic device comprising: At least one processor; and A memory communicatively connected to the at least one processor; wherein, The memory stores a computer program that can be executed by the at least one processor, which enables the at least one processor to perform the automatic reorganization method for bulk pallets in elevated warehouses as described in any embodiment of the present invention.

[0009] According to another aspect of the present invention, a computer-readable storage medium is provided, the computer-readable storage medium storing computer instructions for causing a processor to execute and implement the automatic reorganization method for bulk pallets in a high-bay warehouse as described in any embodiment of the present invention.

[0010] According to another aspect of the present invention, a computer program product is provided, comprising a computer program that, when executed by a processor, implements the automatic reorganization method for bulk pallets in elevated warehouses as described in any embodiment of the present invention.

[0011] The technical solution of this invention involves acquiring real-time inventory data of a high-bay warehouse through a Warehouse Management System (WMS), filtering the real-time inventory data based on preset loose pallet determination conditions to obtain a loose pallet list, and configuring the loose pallet list based on preset outbound rules to obtain an outbound task message. The WMS sends the outbound task message to a dedicated persistent queue for the corresponding loose pallet reassembly task in the message middleware, allowing the Warehouse Control System (WCS) to subscribe to and retrieve the outbound task message. Furthermore, the WCS parses the outbound task message to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target palletizing station, and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target palletizing station, and standard stacking parameters, it generates a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier, and writes the stacker crane scheduling sub-task and the robot scheduling sub-task to the corresponding data block of the Programmable Logic Controller (PLC) to obtain PLC execution instructions. Finally, the PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to standard palletization parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. If it is determined that there are remaining goods after picking up the target loose pallet, the palletizing robot is controlled to enter a full dismantling mode to remove the remaining goods from the target loose pallet, thus completing the loose pallet reassembly task. By organically integrating the WMS business decision-making, reliable transmission of the message middleware, WCS resource scheduling, PLC equipment control, and robot physical execution into an inseparable technical whole, the problems of low automation and poor equipment coordination in the loose pallet reassembly process are solved. This enables automatic reassembly of loose pallets in high-bay warehouses, improving warehouse capacity utilization.

[0012] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a flowchart of an automatic reorganization method for bulk pallets in an elevated warehouse according to Embodiment 1 of the present invention; Figure 2 This is a flowchart of an automatic reorganization method for bulk pallets in an elevated warehouse according to Embodiment 2 of the present invention; Figure 3This is a flowchart of an optional automatic reorganization method for bulk pallets in an elevated warehouse according to Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of an automatic reassembly system for bulk pallets in an elevated warehouse according to Embodiment 3 of the present invention; Figure 5 This is a schematic diagram of the structure of an electronic device that implements the automatic reorganization method for bulk pallets in a high-bay warehouse according to an embodiment of the present invention. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0016] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0017] Example 1 Figure 1 This is a flowchart of an automatic reorganization method for bulk pallets in a high-bay warehouse, provided in Embodiment 1 of the present invention. This embodiment is applicable to the automatic reorganization of bulk pallets in high-bay warehouses. The method can be executed by an automatic reorganization system for bulk pallets in high-bay warehouses. This automatic reorganization system can be implemented in hardware and / or software, and can be configured in an electronic device. For example... Figure 1 As shown, the method includes: S110. Obtain real-time inventory data of the high-bay warehouse through the warehouse management system (WMS), filter the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configure the loose pallet list based on preset outbound rules to obtain an outbound task message.

[0018] In this context, a warehouse management system can refer to the business logic system responsible for decision-making and inventory management at the operational level. A high-bay warehouse refers to a modern warehouse that utilizes high-level shelving to store goods and is equipped with automated storage and retrieval equipment. Inventory data can be the collective term for all data used to describe the storage status of goods in a high-bay warehouse. Real-time inventory data refers to inventory data that is synchronized with the physical warehouse status at millisecond levels.

[0019] The preset loose pallet determination criteria refer to a set of logical rules pre-configured in the WMS for identifying loose pallets. Typically, these criteria include brand matching conditions, time threshold conditions, and item count threshold conditions. Brand matching conditions can be that the goods on the same pallet belong to the same Stock Keeping Unit (SKU). Time threshold conditions can be that the pallet's storage time is greater than or equal to a preset time threshold, such as 24 hours, to prevent newly received loose pallets from being mis-scheduled. Item count threshold conditions can be that the total number of items on the pallet is less than the standard full pallet count, such as 40 items. The loose pallet list refers to a detailed list of pallets that meet the loose pallet determination criteria after being filtered by the WMS. Typically, the loose pallet list is a structured data set, with each record containing at least: pallet identifier (ID), SKU, current item count, storage location coordinates, and storage time. Preset outbound rules refer to the scheduling strategies used by the WMS to determine "which loose pallets to outbound first and how to outbound them." Outbound task messages refer to structured data packets containing complete outbound instructions sent by the WMS to downstream systems. In this embodiment of the invention, the outbound task message includes not only where to retrieve the item, but also where to place it, how to place it, and the task number.

[0020] S120. The outbound task message is sent to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware via WMS, so that the warehouse control system WCS can subscribe to and pull the outbound task message.

[0021] Message middleware can refer to a software infrastructure that supports asynchronous communication. A pallet reassembly task can refer to the entire process of transferring goods from one or more loose pallets onto a new empty pallet using a robotic arm, creating a full or standard pallet. A dedicated persistent queue can refer to a first-in, first-out buffer within the message middleware specifically allocated for tasks like pallet reassembly, where messages are written to disk.

[0022] S130. The outbound task message is parsed through WCS to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier are generated. The stacker crane scheduling sub-task and the robot scheduling sub-task are written to the corresponding data block of the programmable logic controller (PLC) to obtain the PLC execution instructions.

[0023] In this context, the warehouse control system (WMS) refers to the control layer system between the WMS and the equipment. A task identifier (Task ID) is a unique code that identifies a loose pallet reassembly task. For example, T20240520001. Typically, all interactions between the WMS, WCS, and PLC are associated through task identifiers. A loose pallet identifier is a unique code that identifies the currently processed loose pallet. For example, P001. Typically, the loose pallet identifier is used to locate the physical pallet's position on the rack and is the direct basis for stacker crane retrieval. A target empty pallet identifier is a unique code that identifies the empty pallet used to receive reassembled goods. For example, E005. Typically, after reassembly, the target empty pallet identifier replaces the old loose pallet identifier and becomes a new record in the WMS inventory. A target palletizing station refers to a designated fixed physical location in a high-bay warehouse for robotic arms to perform depalletizing and palletizing operations. Standard palletization parameters refer to the mathematical model used to define how goods are placed on pallets. Typically, standard stacking parameters may include: number of items per layer, number of items on the long side, number of items on the short side, layer staggering method, total number of layers, and total height. A stacker crane scheduling subtask refers to a set of instructions generated by the WCS specifically for directing the stacker crane to perform physical handling. Typically, a stacker crane scheduling subtask includes two core actions: picking up loose pallets and picking up empty pallets. A robot scheduling subtask refers to a sequence of operations generated by the WCS specifically for directing the palletizing robot to perform gripping and stacking. Typically, a robot scheduling subtask uses the target palletizing station as the origin and defines the coordinates of the gripping point, the coordinates of the stacking point, the motion trajectory, and the working mode.

[0024] S140. The PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target pallet station according to the standard pallet type parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. When it is determined that there are remaining goods after the target loose pallet is picked up, the palletizing robot is controlled to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet recombination task.

[0025] In this context, a Programmable Logic Controller (PLC) can refer to a digital computing and operating electronic system specifically designed for industrial applications. Typically, a PLC is the direct controller at the device level. PLC execution instructions refer to the final set of control commands generated by the PLC after internal logical operations based on received subtasks. A palletizing robot can refer to an industrial robot used for automatically stacking goods. Typically, a palletizing robot can be a multi-axis articulated robot. A target loose pallet can refer to the physical pallet entity indicated by the loose pallet identifier. Typically, the target loose pallet is the source of the goods. At the palletizing station, it is the object being disassembled. A target empty pallet can refer to the physical pallet entity indicated by the target empty pallet identifier. Typically, the target empty pallet is the destination of the goods. At the palletizing station, it is the object being filled. "Full disassembly mode" can refer to the process of no longer attempting to stack goods according to standard pallet patterns, but instead picking up the remaining small amount of goods on the loose pallet one by one and moving them to a recycling container.

[0026] In an optional implementation, after the PLC determines that there are remaining goods after the target loose pallet is picked up, and controls the palletizing robot to enter a full dismantling mode to remove the remaining goods from the target loose pallet and complete the loose pallet reassembly task, the method further includes: Step a1: Trigger the RFID tag writing operation on the target loose pallet that has completed the loose pallet reorganization task through the WCS. The RFID tag information includes at least the pallet identifier, the type of goods, the actual number of pieces stacked, and the pallet reorganization timestamp.

[0027] Radio Frequency Identification (RFID) refers to a non-contact automatic identification technology that automatically identifies target objects and reads and writes related data through wireless radio frequency signals. In this embodiment of the invention, the RFID chip can be embedded in the pallet, typically a high-frequency or ultra-high-frequency tag, and the reader is installed at the palletizing station and the warehousing aisle. RFID realizes the binding of physical pallets with digital information, which is the technical basis for the consistency between physical goods and accounts. Pallet identification can refer to a unique code that identifies a physical pallet. For example, P_NEW_20240520_008. Typically, pallet identification can be burned into the RFID chip and the WMS database. Goods category can refer to the material attributes of the goods carried on the pallet. For example, the goods category can include SKUs. Actual number of items stacked can refer to the total number of items actually stacked on the target empty pallet by the robot. Typically, the actual number of items stacked can be sent back to the WCS by the PLC counter and then written to the RFID. The palletization timestamp can refer to the system time used to record the completion of the reassembly.

[0028] Step a2: During the process of sending the target bulk pallet into the high-bay warehouse storage location, the WMS performs a secondary RFID reading and verification to compare whether the RFID tag information is consistent with the return information issued by the WCS.

[0029] Among them, a high-bay warehouse storage location can refer to a physical address in a high-bay warehouse that is pre-assigned to pallets after they have been assembled, for long-term storage of goods.

[0030] Step a3: If they match, update the high-bay warehouse inventory ledger through the WMS, deduct the original inventory record corresponding to the target loose pallet, add the inventory record of the reorganized pallet, and update the warehouse capacity occupancy rate simultaneously.

[0031] The high-bay warehouse inventory ledger refers to the logical data table maintained in the Work Management System (WMS). Typically, the high-bay warehouse inventory ledger records information such as the ID, SKU, quantity, storage location, status, and batch for each pallet. The status can include "in stock," "outbound," "locked," or "empty." The original inventory record refers to the original inventory entry in the WMS corresponding to the consumed bulk pallet, i.e., the target bulk pallet. The warehouse capacity utilization rate refers to the ratio of the number of storage spaces currently occupied by valid pallets to the total available storage spaces in the high-bay warehouse.

[0032] Specifically, after the palletizing robot completes the picking and stacking of loose pallets, the PLC feeds back the actual number of stacked items to the WCS. The WCS confirms the completion of palletizing and then sends a write command to the RFID reader. The RFID reader performs a write operation on the RFID tag embedded in the target pallet carrying the reassembled goods at the palletizing station. The written content includes at least: the unique identifier of the pallet, the SKU of the goods, the actual number of stacked items, and the timestamp of palletizing completion. After the write is completed, a read-back verification is performed. If the written data matches the expectation, the WCS marks the palletizing as successful and generates a return-to-warehouse task, sending the same pallet information to the WMS inventory scheduling module; if the write fails, an alarm is triggered and the write is re-written. After three failures, manual intervention is required.

[0033] During the process of the stacker crane transporting the assembled pallets to the target storage location (i.e., the high-bay warehouse storage location), a fixed RFID reader at the entry aisle automatically reads the pallet's RFID tag. The WMS compares the read RFID information with the return information issued by the WCS, including consistency verification of pallet identification, SKU, and quantity. If the comparison matches, the WMS determines that the physical goods match the instructions and performs an inventory ledger update operation: deducting the quantity of the original loose pallet from the corresponding inventory record or deleting the cleared loose pallet record, adding a new inventory record with the reassembled pallet identification as the primary key, including SKU, actual number of pieces stacked, target storage location, and status "in stock," and recalculating and refreshing the current high-bay warehouse capacity occupancy rate; if the comparison does not match, the WMS suspends the entry task and prompts the operator to check to prevent incorrect pallets from entering the inventory. Through the above-mentioned conditional ledger update process of RFID writing and secondary verification, a strict closed loop between the physical result of loose pallet reassembly and the digital ledger is achieved.

[0034] The technical solution of this invention involves acquiring real-time inventory data of a high-bay warehouse through a Warehouse Management System (WMS), filtering the real-time inventory data based on preset loose pallet determination conditions to obtain a loose pallet list, and configuring the loose pallet list based on preset outbound rules to obtain an outbound task message. The WMS sends the outbound task message to a dedicated persistent queue for the corresponding loose pallet reassembly task in the message middleware, allowing the Warehouse Control System (WCS) to subscribe to and retrieve the outbound task message. Furthermore, the WCS parses the outbound task message to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target palletizing station, and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target palletizing station, and standard stacking parameters, it generates a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier, and writes the stacker crane scheduling sub-task and the robot scheduling sub-task to the corresponding data block of the Programmable Logic Controller (PLC) to obtain PLC execution instructions. Finally, the PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to standard palletization parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. If it is determined that there are remaining goods after picking up the target loose pallet, the palletizing robot is controlled to enter a full dismantling mode to remove the remaining goods from the target loose pallet, thus completing the loose pallet reassembly task. By organically integrating the WMS business decision-making, reliable transmission of the message middleware, WCS resource scheduling, PLC equipment control, and robot physical execution into an inseparable technical whole, the problems of low automation and poor equipment coordination in the loose pallet reassembly process are solved. This enables automatic reassembly of loose pallets in high-bay warehouses, improving warehouse capacity utilization.

[0035] Example 2 Figure 2This is a flowchart of an automatic reassembly method for bulk pallets in a high-bay warehouse, provided in Embodiment 2 of the present invention. This embodiment is a refinement based on the above embodiment. Specifically, this embodiment refines the process of "generating a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier using WCS based on the bulk pallet identifier, the target empty pallet identifier, the target palletizing station, and standard pallet type parameters." Specifically, this may include: verifying whether the target palletizing station is idle using WCS, and verifying whether the target empty pallet corresponding to the target empty pallet identifier is not locked and can be retrieved; if both verifications pass, then generating a stacker crane scheduling sub-task based on the target palletizing station using WCS. The stacker crane scheduling sub-task includes at least: a first handling instruction to retrieve the target bulk pallet corresponding to the bulk pallet identifier from the current storage location and transport it to the target palletizing station, and a first handling instruction to remove the target empty pallet corresponding to the target empty pallet identifier from the empty pallet buffer area. A second handling instruction is issued to retrieve and transport the pallet to the target palletizing station, with the second handling instruction having a higher execution priority than the first handling instruction, to ensure that the target empty pallet arrives at the target palletizing station before or simultaneously with the target loose pallet; a robot scheduling subtask is generated by WCS based on the standard stacking parameters, the robot scheduling subtask including at least: a workspace coordinate system established with the target palletizing station as the origin, the source coordinates of the target loose pallet in the workspace coordinate system, the target coordinates of the target empty pallet in the workspace coordinate system, and an action sequence for controlling the palletizing robot to stack goods layer by layer at the target coordinates according to the standard stacking parameters; the stacker scheduling subtask and the robot scheduling subtask are bound to the task identifier by WCS, so that WCS can coordinate the handling and stacking operations under the same loose pallet reassembly task based on the task identifier. Figure 2 As shown, the method includes: S210. Obtain real-time inventory data of the high-bay warehouse through the warehouse management system (WMS), filter the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configure the loose pallet list based on preset outbound rules to obtain an outbound task message.

[0036] Specifically, the Warehouse Management System (WMS) periodically communicates with the underlying database of the high-bay warehouse via a wired network or industrial bus to retrieve real-time snapshots of the entire warehouse inventory, i.e., real-time inventory data. This data includes the unique identifier of each pallet, the SKU of the bound goods, the current number of pieces stacked, the inbound timestamp, and the inventory status. The WMS's built-in loose pallet identification engine then loads preset loose pallet judgment conditions, filtering inventory records that simultaneously meet three constraints: the goods on the same pallet are of a single SKU, the total number of pieces on the pallet is less than the standard full pallet count, and the pallet's inbound time is not less than a preset threshold. After the traversal is complete, a structured loose pallet list is output, in which each record includes the loose pallet identifier, the SKU, the current number of pieces, and the coordinates of its high-bay storage location. Subsequently, the WMS invokes preset outbound rules to aggregate records in the loose pallet list: prioritizing loose pallets with the same SKU and adjacent storage location coordinates, such as those in the same aisle or row, and grouping them into a reassembly task. Each task group is assigned a unique task ID, a pre-locked target empty pallet ID, a specified target palletizing station, and corresponding standard pallet type parameters. Finally, the WMS encapsulates the above structured information into an outbound task message in JSON format. This message serves as a contract connecting the business layer and the execution layer, awaiting delivery to the message middleware.

[0037] S220. Add a priority tag higher than that of a normal replenishment task to the outbound task message through WMS, instruct the message middleware to store the outbound task message in a dedicated persistent queue and enable the consumption confirmation mechanism, and deliver the outbound task message to the dedicated persistent queue.

[0038] In high-bay warehouses, a standard replenishment task refers to the routine operation of moving full pallets of goods from high-bay shelves to the shipping buffer or picking station to meet outbound order demands. Typically, this is the most common and highest-volume task type in high-bay warehouses, with relatively relaxed timeliness requirements. A priority tag refers to a metadata field appended to the message header that identifies the message's processing priority within the message middleware. A consumption acknowledgment mechanism refers to a reliability guarantee feature of the message middleware. Typically, when a consumer, such as WCS, successfully processes a message, it must send an acknowledgment (ACK) to the middleware; if the middleware does not receive an ACK within a specified time, it determines that message processing has failed and automatically puts the message back into the queue for other consumers to consume again.

[0039] Specifically, after WMS generates an outbound task message, it first calls the message middleware client to construct a priority tag for the message, for example, setting priority=10, while the default priority for a regular replenishment task is priority=5, thus declaring that this scattered pallet reorganization task has a higher scheduling weight. Next, WMS sends a queue declaration command to the message middleware, specifying the queue name as `scattered_pallet_task_queue` and configuring the queue attribute as `durable=true`, i.e., a dedicated persistent queue, ensuring that even if the message middleware service restarts, this queue and the messages cached within it will not be lost. Immediately afterward, WMS publishes the outbound task message carrying the priority tag to this persistent queue, enabling the `mandatory` flag and `deliveryMode=2` in the publication parameters, i.e., persistent delivery, and activating the consumption acknowledgment mechanism, i.e., setting `autoAck=false`. This means that the message middleware will store the message on disk and wait for WCS to explicitly provide feedback on the processing result. When WCS connects to the queue as a consumer and pulls a message, the message broker locks the message but does not delete it immediately. Only after WCS successfully parses the message and completes resource verification, sending an explicit ACK signal to the broker, will the broker physically delete the message. If WCS times out or the connection is interrupted, the broker, not receiving an ACK, will automatically re-enqueue the message for WCS to pull again, thus achieving zero-loss and highly reliable delivery of disk reassembly tasks during cross-system transmission.

[0040] S230. The outbound task message is parsed through WCS to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard pallet type parameters corresponding to the loose pallet reassembly task.

[0041] S240. Verify whether the target encoder station is in an idle state through WCS, and verify whether the target empty pallet corresponding to the target empty pallet identifier is not locked and can be retrieved.

[0042] The "idle" status indicates that the palletizing station's resources are not currently occupied by any tasks, and the equipment, such as a robotic arm, can be accessed normally. Typically, palletizing station statuses can include IDLE, BUSY, and FAULT. Only IDLE pallets can be assigned new tasks to prevent two stacker cranes or tasks from competing for the same station. "Locked" indicates that an empty pallet record is marked as assigned to a task and cannot be accessed by other tasks. Locked status is usually indicated by the LOCKED field (occupied by an order). "Available" indicates that an empty pallet physically exists, is in an EMPTY state, is not locked, and its storage location is not blocked.

[0043] S250. If both verifications pass, a stacker crane scheduling subtask is generated by WCS based on the target palletizing station. The stacker crane scheduling subtask includes at least: a first handling instruction to remove the target loose pallet corresponding to the loose pallet identifier from the current storage location and transport it to the target palletizing station; and a second handling instruction to remove the target empty pallet corresponding to the target empty pallet identifier from the empty pallet buffer area and transport it to the target palletizing station. The execution priority of the second handling instruction is higher than that of the first handling instruction, so as to ensure that the target empty pallet arrives at the target palletizing station before or simultaneously with the target loose pallet.

[0044] The current storage location refers to the physical address of the loose pallet in the high-bay warehouse at the current moment. Typically, it can be represented by a triplet of "lane number-column number-layer number", such as A05-03-12. The first handling instruction refers to the instruction segment in the stacker crane subtask used to control the stacker crane to retrieve the target loose pallet from the current storage location and transport it to the target palletizing station. For example, the first handling instruction may include the retrieval coordinates, placement coordinates, running speed curve, and arrival confirmation signal requirements. The empty pallet buffer area refers to a fixed storage area in the high-bay warehouse specifically for storing empty pallets. The second handling instruction refers to the instruction segment in the stacker crane subtask used to control the stacker crane to retrieve the target empty pallet from the empty pallet buffer area and transport it to the same target palletizing station.

[0045] In an optional implementation, after both verifications pass, the method further includes: Step b1: Send a task acceptance receipt to the WMS via WCS.

[0046] The task acceptance receipt refers to a structured confirmation message sent by WCS to WMS after successfully retrieving and parsing the task message from the message middleware and verifying the resources. Typically, a task acceptance receipt includes at least the task_id (consistent with the original task) and status=ACCEPTED (accepted).

[0047] Step b2: Monitor whether the task acceptance receipt is received within the preset timeout period through WMS. If the WMS does not receive the receipt within the timeout period, trigger the re-delivery of the outbound task message.

[0048] The preset timeout refers to the maximum allowed time for the WMS to wait for a task acceptance confirmation after sending an outbound task message. For example, the preset timeout can be 3 seconds or 5 seconds. Typically, the preset timeout can be pre-configured based on the system's average processing latency and network jitter.

[0049] Specifically, after parsing the outbound task message and verifying the target code disk workstation and target empty tray resources, WCS can first construct a task acceptance receipt JSON object. This task acceptance receipt JSON object must contain at least the fields {"task_id":"T20240520001","result":"ACCEPTED","timestamp":1716182400}, and send it to WMS through the interface with WMS or the message middleware reply queue. When WMS initially calls the message middleware to deliver the outbound task message, it starts a timer with a preset timeout of 3000ms. If the WMS receives a task acceptance acknowledgment with a matching task_id within 3000ms, it marks the task status as "accepted (ACKED)," cancels the timer, and waits for feedback from subsequent subtask execution. If no matching acknowledgment is received by the timer expiration, the WMS determines that the task delivery is abnormal. Based on the task_id and idempotency flag carried in the original outbound task message, it re-delivers the task to the same dedicated persistent queue (re-delivery count +1) and resets the timer. When the cumulative number of re-deliveries reaches a preset limit, such as 3 times, and there is still no acknowledgment, the WMS sets the task status to "failed," generates an alarm, and pushes it to the monitoring interface, prompting the operator to manually investigate WCS or network communication failures. Through the above acknowledgment feedback and timeout re-delivery mechanism, it is ensured that each disk reassembly task is either confirmed and accepted by the WCS or promptly detected and rescheduled, achieving a reliable task handshake between the WMS and WCS.

[0050] S260. Based on the standard palletization parameters, generate a robot scheduling subtask using WCS. The robot scheduling subtask includes at least: a workspace coordinate system established with the target palletizing station as the origin, the source coordinates of the target loose pallet in the workspace coordinate system, the target coordinates of the target empty pallet in the workspace coordinate system, and an action sequence for controlling the palletizing robot to stack goods layer by layer at the target coordinates according to the standard palletization parameters.

[0051] The workspace coordinate system refers to a three-dimensional Cartesian coordinate system (XYZ) with a preset reference point at the pallet station as its origin. Typically, the pallet corner or station origin can be used as the origin, and this workspace coordinate system describes the pose of the robot's end effector relative to the station. The source coordinates refer to the theoretical center coordinates of the item to be picked up on the loose pallet within the workspace coordinate system of the pallet station. Typically, the source coordinates can be calculated based on the stacking pattern of the loose pallet in its standard position. The target coordinates refer to the position coordinates of the next item to be stacked on an empty pallet, calculated according to standard stacking parameters, within the workspace coordinate system of the pallet station. Typically, the target coordinates can be dynamically calculated from standard stacking parameters, such as the number of items per layer, row and column spacing, layer height, and the number of items already stacked. The action sequence refers to the ordered set of basic action instructions required for the robot to complete one "grab-move-stack" operation. Typically, the action sequence may include: move to the source coordinates → activate the vacuum suction cup → delay to confirm suction → lift → translate to the target coordinates → lower → deactivate the vacuum suction cup → return to the standby point.

[0052] S270. Bind the stacker crane scheduling subtask and the robot scheduling subtask to the task identifier through WCS, so that WCS can coordinate the handling and stacking operations under the same loose pallet reassembly task based on the task identifier, and write the stacker crane scheduling subtask and the robot scheduling subtask to the corresponding data block of the programmable logic controller (PLC) to obtain the PLC execution instruction.

[0053] Specifically, after WCS subscribes to and successfully retrieves the outbound task message from the dedicated persistent queue in the message middleware, it parses the task identifier (Task_ID), the pallet identifier (Pallet_P001), the target empty pallet identifier (EP_005), the target pallet racking station (ST_01), and the standard pallet type parameters (40 pieces / pallet, 20×5 per layer, 3 layers plus adjustment for the top layer). WCS first queries the internally maintained resource status table: checking if the current status field of ST_01 is IDLE, and checking if the inventory status of the empty pallet EP_005 is EMPTY and the lock field is NULL. If either condition is not met, WCS re-enqueues the message and sets a delay for retry; if both conditions are met, WCS immediately sets the status of ST_01 to BUSY and EP_005 to LOCKED (bound to Task_ID), completing resource reservation. Subsequently, WCS generates a stacker crane scheduling subtask: a second handling instruction, instructing the stacker crane to retrieve EP_005 from the empty pallet buffer storage location (A_00-02-01) and transport it to ST_01, this instruction is marked with a higher execution priority; and a first handling instruction, instructing the stacker crane to retrieve Pallet_P001 from the current loose pallet storage location (A_05-10-03) and transport it to the same ST_01, with a lower priority. Both instructions are encapsulated in the same subtask package and associated with a Task_ID. Simultaneously, WCS generates a robot scheduling subtask: establishing a right-handed workspace coordinate system O-XYZ with the left front corner of ST_01 as the origin; calculating the source coordinates (Xs,Ys,Zs) based on the theoretical parking position of Pallet_P001 on the workstation and the center of the visible goods at the top layer; calculating the row and column index (i,j,k) of the (n+1)th item to be placed on the empty pallet EP_005 according to the standard stacking parameters and the stacking counter n, and mapping it to the target coordinates (Xt,Yt,Zt)=O+(i×dx,j×dy,k×dz); defining the action sequence: {MoveTo(Xs,Ys,Zs),VacuumON,Dwell(t_adsorb),Lift(delta_z),MoveTo(Xt,Yt,Zt),Lower(delta_z),VacuumOFF,Retract}, and executing it in a loop until the standard stacking quantity is reached or there are no more loose pallets to grab. The robot scheduling subtask is also bound to Task_ID. Finally, WCS writes the stacker crane scheduling subtask and the robot scheduling subtask into the corresponding data blocks of the PLC through the Open Platform Communications Unified Architecture - Industrial Grade Communication Protocol (OPC UA), and waits for the PLC to execute and provide feedback.Since the two subtasks share the same Task_ID, WCS can arbitrarily associate the stacker crane arrival event with the robot start permission in subsequent monitoring, thereby achieving coordinated scheduling of handling and stacking.

[0054] S280. The joint motion parameters and suction cup control signals of the palletizing robot are obtained by mapping the instructions executed by the PLC.

[0055] The joint motion parameters can refer to the angle values, velocities, accelerations, and transition modes that each servo axis should reach, obtained by the PLC from the inverse kinematics model of the robot arm, which is derived from the target pose in Cartesian space. The suction cup control signal can refer to a set of digital or analog signals output by the PLC to the vacuum generating unit or solenoid valve. For example, the suction cup control signal may include at least: vacuum on (Vac_ON), ​​vacuum off (Vac_OFF), vacuum breaking (Blow_OFF), and optional pressure threshold judgment feedback.

[0056] S290. The PLC controls the palletizing robot to move to the gripping position of the target tray corresponding to the tray identifier based on the joint motion parameters, and controls the vacuum suction cup to adsorb the goods on the target tray based on the suction cup control signal.

[0057] Among them, the grasping pose can refer to the spatial pose that the end effector of the robot arm should reach in the workspace coordinate system of the encoder station, so that the center of the suction cup is aligned with the center of the surface of the product to be grasped.

[0058] S2100: The PLC calculates the target stacking posture on the target empty pallet corresponding to the target empty pallet identifier based on the standard stacking parameters, controls the palletizing robot to move to the target stacking posture based on the updated joint motion parameters, and controls the vacuum suction cup to release the goods based on the suction cup control signal to complete a single gripping and stacking action.

[0059] The target stacking pose can refer to the spatial pose of the robot end effector, which should be reached in the workspace coordinate system of the stacking station so that the center of the suction cup is aligned with the Nth stacking point calculated according to the standard stacking parameters on the empty pallet.

[0060] Specifically, after receiving the stacker crane picking sub-task and the robotic arm pallet assembly task written to the data block by the WCS via OPC UA, the PLC first parses out the standard stack type parameters (20×5 pieces per layer, layer spacing H_layer, pallet corner coordinates P0) and the origin O of the workspace coordinate system (corresponding to the target pallet station reference). Then, for the nth item to be picked up: first, the PLC reads the source coordinates Ps_src (the theoretical position of the nth item on the loose pallet in the station coordinate system) sent by the WCS, performs tool center point offset and Z-axis pre-pressure compensation to obtain the picking pose Pose_grasp; calls the built-in inverse kinematics algorithm to map Pose_grasp to the six-axis joint motion parameters J_grasp=[J1…J6], and generates the suction cup control signal Seq_suction={Vac_ON after reach, Dwell 200ms for pressure OK}. Afterwards, the PLC drives the robot arm to move along each axis according to an S-shaped speed curve to J_grasp. Once in position, it executes Vac_ON and waits for the vacuum pressure sensor to report a value higher than the set threshold, such as -60kPa. If the threshold is not met within the timeout period, a retry or alarm is triggered. Further, the PLC calculates the target stacking pose based on the stacking counter k and standard stacking parameters: row, column, and layer indices (i,j,k) → Cartesian coordinates Pt = P0 + i × dx + j × dy + k × H_layer; considering the robot arm's posture, the placement pose Pose_place is obtained; similarly, the inverse solution yields the joint motion parameters J_place. Finally, the PLC drives the robot arm to move to J_place, slightly lowers the Z-axis to the contact point, and executes Vac_OFF or a short-term Blow_OFF release. After confirming the vacuum is released, it is raised to a safe height, k = k + 1. This process is repeated until the WCS indicates that there are no more items to grab from the tray, reaching the standard number of items, or the remaining items are less than the minimum number to grab, triggering a full dismantling. Through this process, standard pallet parameters are converted in real time into specific target stacking poses and joint motion parameters, and the robot strictly follows the specifications to complete the transfer and stacking of loose goods to target empty pallets.

[0061] S2110. The PLC determines the number of remaining items on the target tray according to the tail-end triggering condition issued by the WCS. When the number of remaining items after the target tray is grabbed is less than the minimum number of items grabbed in a single operation, or when the number of remaining items on the target tray is greater than zero after the tray is assembled, the WCS sends a tail-end flag bit to the PLC.

[0062] The tail tray trigger condition refers to a set of logical judgment rules issued by the WCS to the PLC. Typically, the tail tray trigger condition is used to determine when a currently loose pallet is considered a tail tray that cannot continue normal palletizing. The minimum number of items to be picked up in a single operation refers to the minimum number of items that the vacuum suction cup array of the palletizing robot can reliably pick up in one gripping action. Typically, the minimum number of items to be picked up in a single operation depends on the size of the items and the arrangement of the suction cups. For example, the minimum number of items to be picked up in a single operation can be set to 2 or 3 items. The tail tray flag bit refers to a Boolean value or enumerated flag bit written by the WCS to the PLC via OPC UA or IO mapping. Typically, the tail tray flag bit is used to notify the PLC to switch the robot from normal palletizing mode to full disassembly mode.

[0063] S2120. The PLC responds to the tail tray flag position, switches the working mode of the palletizing robot to full disassembly mode, controls the palletizing robot to move one by one to the gripping position of the remaining goods on the target loose tray, and adsorbs and removes the remaining goods to the preset tail tray recycling container based on the suction cup control signal.

[0064] Among them, the tail-end recycling container can refer to a special container located next to or at a separate workstation, used to temporarily receive small items removed from the tail-end, so that they can be manually sorted or reassembled later.

[0065] S2130. After the target tray is cleared, the PLC controls the original tray to return to the buffer area as an empty tray.

[0066] Here, the original loose pallet can refer to a physical pallet that has been removed for reorganization and has been completely dismantled and emptied of goods. For example, the original loose pallet can be the physical pallet corresponding to the target loose pallet.

[0067] Specifically, the WCS issues a remaining pallet trigger condition to the PLC based on standard stacking pattern parameters and the initial number of items on the loose pallet: the number of remaining items < the minimum single grasping quantity (Min_Grasp_Qty); the number of remaining items after pallet grouping is completed > 0. After each normal grasping-stacking cycle is completed, the PLC reads the current loose pallet remaining item count variable Remain_N and compares it with the remaining pallet trigger condition. When Remain_N < Min_Grasp_Qty, or the pallet grouping has reached the full pallet item count and Remain_N > 0, the WCS writes the Tail_Mode_Enable bit in the data block to TRUE (i.e., the remaining pallet flag bit) via OPC UA. After the PLC detects that the flag bit is TRUE, it immediately stops the standard stacking pattern logic, and switches the manipulator working mode to the full disassembly mode: first, the PLC takes the center of each visible goods of the loose pallet in the workspace coordinate system of the station as the grasping pose, sequentially moves the manipulator to each remaining goods position, outputs Vac_ON for adsorption, confirms that the vacuum pressure reaches the standard, then lifts the manipulator, moves it above the remaining pallet recovery container, outputs Vac_OFF or a short Blow_OFF to release the goods, and the container cumulative count is incremented by 1; after that, every time one item is moved out, Remain_N ← Remain_N - 1, and the cycle is executed until Remain_N = 0; further, it is confirmed that the original loose pallet is empty, the PLC feeds back Tail_Cleared=TRUE to the WCS, the WCS releases the lock on the pallet and updates the status to EMPTY (empty pallet), notifies the stacker to transport it from the palletizing station back to the empty pallet buffer area, and the original storage location is released; finally, the WCS clears the Tail_Mode_Enable flag bit, and the PLC returns to standby or continues the next task. If the remaining pallet recovery container is full, the PLC triggers a relay signal, and the WMS arranges to transfer it to the manual sorting table or the re-palletizing queue. Through the above process, any situation that results in a loose pallet with a small number of residual items can be automatically identified and fully disassembled without manual intervention.

[0068] The technical solution of this invention involves acquiring real-time inventory data from a high-bay warehouse through a Warehouse Management System (WMS), filtering the real-time inventory data based on preset loose pallet determination conditions to obtain a loose pallet list, and configuring the loose pallet list based on preset outbound rules to obtain outbound task messages. The WMS adds a priority tag higher than that of ordinary replenishment tasks to the outbound task messages, instructing the message middleware to store the outbound task messages in a dedicated persistent queue and enable a consumption confirmation mechanism, and then delivers the outbound task messages to this dedicated persistent queue. The WCS parses the outbound task messages to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target palletizing station, and standard pallet type parameters corresponding to the loose pallet reassembly task. The WCS verifies whether the target palletizing station is idle and whether the target empty pallet corresponding to the target empty pallet identifier is not locked and can be retrieved. If both verifications pass, a stacker crane scheduling subtask is generated based on the target palletizing station using WCS. This subtask includes at least: a first handling instruction to retrieve the target loose pallet corresponding to the loose pallet identifier from its current storage location and transport it to the target palletizing station; and a second handling instruction to retrieve the target empty pallet corresponding to the target empty pallet identifier from the empty pallet buffer area and transport it to the target palletizing station. The second handling instruction has a higher execution priority than the first handling instruction to ensure that the target empty pallet arrives at the target palletizing station before or simultaneously with the target loose pallet. A robot scheduling subtask is also generated based on standard palletization parameters using WCS. This subtask includes at least: a workspace coordinate system established with the target palletizing station as the origin; the source coordinates of the target loose pallet in the workspace coordinate system; the target coordinates of the target empty pallet in the workspace coordinate system; and an action sequence for controlling the palletizing robot to stack goods layer by layer at the target coordinates according to the standard palletization parameters. By binding task identifiers to both the stacker crane scheduling subtask and the robot scheduling subtask through the Workspace Control System (WCS), the WCS can coordinate the handling and stacking operations under the same loose pallet reassembly task based on the task identifiers. The stacker crane scheduling subtask and the robot scheduling subtask are written to the corresponding data blocks of the Programmable Logic Controller (PLC) to obtain PLC execution instructions. The PLC maps the joint motion parameters and suction cup control signals of the palletizing robot according to the PLC execution instructions. Based on the joint motion parameters, the PLC controls the palletizing robot to move to the gripping posture of the target loose pallet corresponding to the loose pallet identifier, and controls the vacuum suction cup to pick up the goods on the target loose pallet based on the suction cup control signals. The PLC calculates the target stacking posture on the target empty pallet corresponding to the target empty pallet identifier based on the standard pallet type parameters, controls the palletizing robot to move to the target stacking posture based on the updated joint motion parameters, and controls the vacuum suction cup to release the goods based on the suction cup control signals, thus completing a single gripping and stacking action.The PLC determines the remaining number of items on the target pallet based on the end-of-pallet trigger conditions issued by the WCS. When the remaining number of items after the target pallet is grabbed is less than the minimum number of items to be grabbed in a single operation, or when the remaining number of items after palletization is greater than zero, the WCS sends an end-of-pallet flag to the PLC. In response to the end-of-pallet flag, the PLC switches the palletizing robot's operating mode to full dismantling mode, controlling the robot to move one by one to the grabbing position of the remaining items on the target pallet. Based on suction cup control signals, the robot then picks up and removes the remaining items to a pre-set end-of-pallet recycling container. After the target pallet is emptied, the PLC controls the original pallet to return to the buffer area as an empty pallet. By organically integrating the WMS's business decisions, reliable message middleware transmission, WCS resource scheduling, PLC equipment control, and robot physical execution into an inseparable technical whole, the problems of low automation and poor equipment coordination in the pallet reorganization process are solved. This enables automatic reorganization of pallets in high-bay warehouses, improving warehouse capacity utilization.

[0069] Figure 3 The diagram shows a flowchart of an optional automatic reorganization method for loose pallets in a high-bay warehouse, provided by an embodiment of the present invention. Specifically, firstly, the Warehouse Management System (WMS) identifies pallets that meet the reorganization criteria based on a "brand number + time threshold + number of pieces threshold" selection condition and generates an initial reorganization instruction. The WMS then converts the selection results into a standardized reorganization outbound order (i.e., a loose pallet list), which serves as the basis for execution by downstream systems. Next, the Warehouse Control System (WCS) receives the outbound order and, combined with resource information, performs task scheduling and resource allocation. Further, the PLC, according to the instructions issued by the WCS (including joint motion parameters mapped from standard pallet type parameters), drives a robotic arm to disassemble the loose pallets, transferring goods from the original loose pallet to the target pallet. If the number of remaining goods is less than the preset minimum number of pieces to be grabbed at once, a full disassembly mode for the remaining pallets is triggered, and the robotic arm moves each piece into the remaining pallet recycling container. After the pallet assembly is completed, WCS triggers the RFID tag writing command, which is then processed through a four-level scheduling protocol: WMS → JSON message queue → WCS → OPC UA → PLC → Modbus → pallet assembly software, to achieve cross-system collaboration. During the return process, WMS performs a second RFID reading verification. If the verification is consistent, the original loose pallet inventory is deducted, the reassembled pallet inventory is added, and the warehouse capacity occupancy rate is updated, completing the entire closed-loop process.

[0070] Example 3 Figure 4 This is a schematic diagram of an automatic reassembly system for bulk pallets in a high-bay warehouse, provided in Embodiment 3 of the present invention. Figure 4 As shown, the system includes: a warehouse management system 310, a warehouse control system 320, and a programmable logic controller 330; Among them, the warehouse management system WMS 310 is used to obtain real-time inventory data of the high-bay warehouse, filter the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configure the loose pallet list based on preset outbound rules to obtain outbound task messages. WMS 310 is used to send the outbound task message to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware, so that the warehouse control system WCS 320 can subscribe to and pull the outbound task message. WCS 320 is used to parse the outbound task message to obtain the task identifier, pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, it generates a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier. The stacker crane scheduling sub-task and the robot scheduling sub-task are written to the corresponding data block of the programmable logic controller PLC 330 to obtain the PLC execution instruction. PLC 330 is used to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier and place them on the target empty pallet corresponding to the target empty pallet identifier according to the standard pallet type parameters at the target palletizing station. When it is determined that there are remaining goods after the target loose pallet is picked up, the palletizing robot is controlled to enter the full disassembly mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reassembly task.

[0071] The technical solution of this invention includes a warehouse management system (WMS) 310, which acquires real-time inventory data from the high-bay warehouse, filters the real-time inventory data based on preset loose pallet judgment conditions to obtain a loose pallet list, and configures the loose pallet list based on preset outbound rules to obtain an outbound task message. The WMS 310 sends the outbound task message to a dedicated persistent queue for the corresponding loose pallet reassembly task in the message middleware, so that the warehouse control system (WCS) 320 can subscribe to and retrieve the outbound task message. The WCS 320 parses the outbound task message to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station, and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station, and standard stacking parameters, it generates a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier, and writes the stacker crane scheduling sub-task and the robot scheduling sub-task to the corresponding data block of the programmable logic controller (PLC) 330 to obtain PLC execution instructions. The 330 is used to drive a palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to standard palletization parameters, and place them on the target empty pallet corresponding to the target empty pallet identifier. If it determines that there are remaining goods after picking up the target loose pallet, it controls the palletizing robot to enter a full dismantling mode to remove the remaining goods from the target loose pallet, thus realizing the loose pallet reassembly task. By organically integrating the business decision-making of the WMS, the reliable transmission of the message middleware, the resource scheduling of the WCS, the equipment control of the PLC, and the physical execution of the robot into an inseparable technical whole, the problems of low automation and poor equipment coordination in the loose pallet reassembly process are solved. This enables automatic reassembly of loose pallets in high-bay warehouses, improving warehouse capacity utilization.

[0072] Optionally, the warehouse control system 320 can be used to: verify whether the target palletizing station is idle, and verify whether the target empty pallet corresponding to the target empty pallet identifier is not locked and can be retrieved; if both verifications pass, a stacker crane scheduling subtask is generated based on the target palletizing station. The stacker crane scheduling subtask includes at least: a first handling instruction to retrieve the target loose pallet corresponding to the loose pallet identifier from the current storage location and transport it to the target palletizing station, and a second handling instruction to retrieve the target empty pallet corresponding to the target empty pallet identifier from the empty pallet buffer area and transport it to the target palletizing station, wherein the execution priority of the second handling instruction is higher than that of the target empty pallet identifier. The first handling instruction is given to ensure that the target empty pallet arrives at the target palletizing station before or simultaneously with the target loose pallet; based on the standard palletization parameters, a robot scheduling subtask is generated, which includes at least: a workspace coordinate system established with the target palletizing station as the origin, the source coordinates of the target loose pallet in the workspace coordinate system, the target coordinates of the target empty pallet in the workspace coordinate system, and an action sequence for controlling the palletizing robot to stack goods layer by layer at the target coordinates according to the standard palletization parameters; the stacker crane scheduling subtask and the robot scheduling subtask are both bound to the task identifier, so that the WCS 320 can coordinate the handling and stacking operations under the same loose pallet reassembly task based on the task identifier.

[0073] Optionally, the warehouse control system 320 can also be used to: send a task acceptance receipt to the WMS 310 after both have passed the verification. WMS 310 is used to monitor whether it receives the task acceptance receipt within a preset timeout period. If WMS 310 does not receive the receipt within the timeout period, it triggers the re-delivery of the outbound task message.

[0074] Optionally, the programmable logic controller 330 can be used to: map the joint motion parameters of the palletizing robot and the suction cup control signal according to the PLC execution instructions; control the palletizing robot to move to the gripping posture of the target loose pallet corresponding to the loose pallet identifier based on the joint motion parameters, and control the vacuum suction cup to adsorb the goods on the target loose pallet based on the suction cup control signal; calculate the target stacking posture on the target empty pallet corresponding to the target empty pallet identifier according to the standard pallet type parameters, control the palletizing robot to move to the target stacking posture based on the updated joint motion parameters, and control the vacuum suction cup to release the goods based on the suction cup control signal, so as to complete a single gripping and stacking action.

[0075] Optionally, the programmable logic controller 330 can be used to: numerically determine the number of remaining items on the target tray based on the tail-end trigger condition issued by the WCS 320; when the number of remaining items after the target tray is grabbed is less than the minimum number of items to be grabbed in a single operation, or when the number of remaining items on the target tray is greater than zero after the tray is assembled, the WCS 320 sends a tail-end flag bit to the PLC 330; in response to the tail-end flag bit, switch the working mode of the palletizing robot to the full disassembly mode, control the palletizing robot to move one by one to the grabbing position of the remaining items on the target tray, and adsorb and remove the remaining items to the preset tail-end recycling container based on the suction cup control signal; after the target tray is emptied, control the original tray to return to the buffer area as an empty tray.

[0076] Optionally, the warehouse control system 320 can also be used to: when the PLC 330 determines that there are remaining goods after the target loose pallet is grabbed, control the palletizing robot to enter the full disassembly mode to remove the remaining goods from the target loose pallet and complete the loose pallet reassembly task, and then trigger the RFID tag writing operation on the target loose pallet that has completed the loose pallet reassembly task. The RFID tag information includes at least the pallet identifier, goods category, actual number of pieces stacked and pallet assembly timestamp. WMS 310 is used to perform secondary RFID reading verification during the process of sending the target bulk pallet into the high-bay warehouse storage location, and to compare whether the RFID tag information is consistent with the return information issued by WCS 320; if they are consistent, the high-bay warehouse inventory ledger is updated, the original inventory record corresponding to the target bulk pallet is deducted, and the inventory record of the reassembled pallet is added, and the warehouse capacity occupancy rate is updated synchronously.

[0077] Optionally, the warehouse management system 310 can be used to: add a priority tag higher than that of a normal replenishment task to the outbound task message, instruct the message middleware to store the outbound task message in a dedicated persistent queue and enable the consumption confirmation mechanism, and deliver the outbound task message to the dedicated persistent queue.

[0078] The automatic reorganization system for bulk pallets in elevated warehouses provided in this embodiment of the invention can execute the automatic reorganization method for bulk pallets in elevated warehouses provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the method.

[0079] Example 4 Figure 5A schematic diagram of an electronic device 410 that can be used to implement embodiments of the present invention is shown. The electronic device is intended to represent various forms of digital computers, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. The electronic device can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smartphones, wearable devices (e.g., helmets, glasses, watches, etc.), and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the invention described and / or claimed herein.

[0080] like Figure 5 As shown, the electronic device 410 includes at least one processor 420 and a memory, such as a read-only memory (ROM) 430 or a random access memory (RAM) 440, communicatively connected to the at least one processor 420. The memory stores computer programs executable by the at least one processor. The processor 420 can perform various appropriate actions and processes based on the computer program stored in the ROM 430 or loaded into the RAM 440 from storage unit 490. The RAM 440 may also store various programs and data required for the operation of the electronic device 410. The processor 420, ROM 430, and RAM 440 are interconnected via a bus 450. An input / output (I / O) interface 460 is also connected to the bus 450.

[0081] Multiple components in electronic device 410 are connected to I / O interface 460, including: input unit 470, such as keyboard, mouse, etc.; output unit 480, such as various types of monitors, speakers, etc.; storage unit 490, such as disk, optical disk, etc.; and communication unit 4100, such as network card, modem, wireless transceiver, etc. Communication unit 4100 allows electronic device 410 to exchange information / data with other devices through computer networks such as the Internet and / or various telecommunications networks.

[0082] Processor 420 can be a variety of general-purpose and / or special-purpose processing components with processing and computing capabilities. Some examples of processor 420 include, but are not limited to, a central processing unit (CPU), a graphics processing unit (GPU), various special-purpose artificial intelligence (AI) computing chips, various processors running machine learning model algorithms, a digital signal processor (DSP), and any suitable processor, controller, microcontroller, etc. Processor 420 performs the various methods and processes described above, such as the automatic reorganization method for high-bay warehouse inventory.

[0083] The method includes: The warehouse management system (WMS) obtains real-time inventory data of the high-bay warehouse, filters the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configures the loose pallet list based on preset outbound rules to obtain outbound task messages. The outbound task message is sent to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware via WMS, so that the warehouse control system WCS can subscribe to and pull the outbound task message. The outbound task message is parsed by WCS to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier are generated. The stacker crane scheduling sub-task and the robot scheduling sub-task are written to the corresponding data block of the programmable logic controller (PLC) to obtain the PLC execution instructions. The PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to the standard pallet type parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. When it is determined that there are remaining goods after the target loose pallet is picked up, the palletizing robot is controlled to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reorganization task.

[0084] In some embodiments, the automatic reorganization method for bulk pallets in a high-bay warehouse can be implemented as a computer program tangibly contained in a computer-readable storage medium, such as storage unit 490. In some embodiments, part or all of the computer program can be loaded and / or mounted on electronic device 410 via ROM 430 and / or communication unit 4100. When the computer program is loaded into RAM 440 and executed by processor 420, one or more steps of the automatic reorganization method for bulk pallets in a high-bay warehouse described above can be performed. Alternatively, in other embodiments, processor 420 can be configured to perform the automatic reorganization method for bulk pallets in a high-bay warehouse by any other suitable means (e.g., by means of firmware).

[0085] Various embodiments of the systems and techniques described above herein can be implemented in digital electronic circuit systems, integrated circuit systems, field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), application-specific standard products (ASSPs), system-on-a-chip (SoCs), complex programmable logic devices (CPLDs), computer hardware, firmware, software, and / or combinations thereof. These various embodiments may include implementations in one or more computer programs that can be executed and / or interpreted on a programmable system including at least one programmable processor, which may be a dedicated or general-purpose programmable processor, capable of receiving data and instructions from a storage system, at least one input device, and at least one output device, and transmitting data and instructions to the storage system, the at least one input device, and the at least one output device.

[0086] Computer programs used to implement the methods of the present invention may be written in any combination of one or more programming languages. These computer programs may be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device, such that when executed by the processor, the computer programs cause the functions / operations specified in the flowcharts and / or block diagrams to be performed. The computer programs may be executed entirely on a machine, partially on a machine, or as a standalone software package, partially on a machine and partially on a remote machine, or entirely on a remote machine or server.

[0087] In the context of this invention, a computer-readable storage medium can be a tangible medium that may contain or store a computer program for use by or in conjunction with an instruction execution system, apparatus, or device. A computer-readable storage medium may include, but is not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatus, or devices, or any suitable combination thereof. Alternatively, a computer-readable storage medium may be a machine-readable signal medium. More specific examples of machine-readable storage media include electrical connections based on one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof.

[0088] To provide interaction with a user, the systems and techniques described herein can be implemented on an electronic device having: a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user; and a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the electronic device. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form (including sound input, voice input, or tactile input).

[0089] The systems and technologies described herein can be implemented in computing systems that include backend components (e.g., as data servers), or middleware components (e.g., application servers), or frontend components (e.g., user computers with graphical user interfaces or web browsers through which users can interact with implementations of the systems and technologies described herein), or any combination of such backend, middleware, or frontend components. The components of the system can be interconnected via digital data communication of any form or medium (e.g., communication networks). Examples of communication networks include local area networks (LANs), wide area networks (WANs), blockchain networks, and the Internet.

[0090] A computing system can include clients and servers. Clients and servers are generally located far apart and typically interact through communication networks. The client-server relationship is created by computer programs running on the respective computers and having a client-server relationship with each other. The server can be a cloud server, also known as a cloud computing server or cloud host, which is a hosting product within the cloud computing service system to address the shortcomings of traditional physical hosts and VPS services, such as high management difficulty and weak business scalability.

[0091] This application also discloses a computer program product, which includes a computer program that, when executed by a processor, implements the automatic reorganization method for bulk pallets in elevated warehouses provided in any embodiment of this application. This program product shares the same inventive concept as the automatic reorganization method for bulk pallets in elevated warehouses disclosed in the embodiments of this application, and therefore will not be described in detail here.

[0092] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0093] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. An automatic reassembly method for loose pallets in an elevated warehouse, characterized in that, The method is applied to an automated reassembly system for loose pallets in a high-bay warehouse, which includes a Warehouse Management System (WMS), message middleware, Warehouse Control System (WCS), Programmable Logic Controller (PLC), and a palletizing robot. The method includes: The warehouse management system (WMS) obtains real-time inventory data of the high-bay warehouse, filters the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configures the loose pallet list based on preset outbound rules to obtain outbound task messages. The outbound task message is sent to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware via WMS, so that the warehouse control system WCS can subscribe to and pull the outbound task message. The outbound task message is parsed by WCS to obtain the task identifier, loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, a stacker crane scheduling sub-task and a robot scheduling sub-task bound to the task identifier are generated. The stacker crane scheduling sub-task and the robot scheduling sub-task are written to the corresponding data block of the programmable logic controller (PLC) to obtain the PLC execution instructions. The PLC executes instructions to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier at the target palletizing station according to the standard pallet type parameters and place them on the target empty pallet corresponding to the target empty pallet identifier. When it is determined that there are remaining goods after the target loose pallet is picked up, the palletizing robot is controlled to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reorganization task.

2. The method according to claim 1, characterized in that, The process of generating stacker crane scheduling sub-tasks and robot scheduling sub-tasks bound to the task identifier using WCS based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station, and standard stacking type parameters includes: The WCS is used to verify whether the target encoder station is in an idle state, and to verify whether the target empty pallet corresponding to the target empty pallet identifier is not locked and can be retrieved. If both verifications pass, a stacker crane scheduling subtask is generated by WCS based on the target palletizing station. The stacker crane scheduling subtask includes at least: a first handling instruction to take the target loose pallet corresponding to the loose pallet identifier from the current storage location and transport it to the target palletizing station; and a second handling instruction to take the target empty pallet corresponding to the target empty pallet identifier from the empty pallet buffer area and transport it to the target palletizing station. The execution priority of the second handling instruction is higher than that of the first handling instruction, so as to ensure that the target empty pallet arrives at the target palletizing station before or simultaneously with the target loose pallet. Based on the standard palletization parameters, WCS generates a robot scheduling subtask. The robot scheduling subtask includes at least: a workspace coordinate system established with the target palletizing station as the origin, the source coordinates of the target loose pallet in the workspace coordinate system, the target coordinates of the target empty pallet in the workspace coordinate system, and an action sequence for controlling the palletizing robot to stack goods layer by layer at the target coordinates according to the standard palletization parameters. By binding the stacker crane scheduling subtask and the robot scheduling subtask to the task identifier through WCS, the WCS can coordinate the handling and stacking operations under the same loose pallet reassembly task based on the task identifier.

3. The method according to claim 2, characterized in that, After both verifications pass, the following is also included: The task acceptance receipt is sent back to the WMS via the WCS. The system monitors whether it receives the task acceptance receipt within a preset timeout period via WMS. If the WMS does not receive the receipt within the timeout period, it triggers a re-delivery of the outbound task message.

4. The method according to claim 1, characterized in that, The process of driving a palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier and stack them onto the target empty pallet corresponding to the target empty pallet identifier at the target palletizing station according to the standard pallet type parameters, via PLC execution instructions, includes: The joint motion parameters and suction cup control signals of the palletizing robot are obtained by mapping the instructions executed by the PLC. The PLC controls the palletizing robot to move to the gripping position of the target tray corresponding to the tray identifier based on the joint motion parameters, and controls the vacuum suction cup to adsorb the goods on the target tray based on the suction cup control signal. The PLC calculates the target stacking posture on the target empty pallet corresponding to the target empty pallet identifier based on the standard stacking parameters. Based on the updated joint motion parameters, the palletizing robot is controlled to move to the target stacking posture, and the vacuum suction cup is controlled to release the goods based on the suction cup control signal to complete a single gripping and stacking action.

5. The method according to claim 4, characterized in that, When the PLC determines that there are remaining goods after the target loose pallet is picked up, it controls the palletizing robot to enter a full dismantling mode to remove the remaining goods from the target loose pallet, including: The PLC determines the number of remaining items on the target tray based on the end-of-tray trigger condition issued by the WCS. When the number of remaining items on the target tray is less than the minimum number of items to be grabbed in a single operation, or when the number of remaining items on the target tray is greater than zero after the tray is assembled, the WCS sends an end-of-tray flag to the PLC. The PLC responds to the tail tray flag position, switches the working mode of the palletizing robot to full disassembly mode, controls the palletizing robot to move one by one to the gripping position of the remaining goods on the target loose tray, and adsorbs and removes the remaining goods to the preset tail tray recycling container based on the suction cup control signal. After the target tray is emptied, the PLC controls the original tray to return to the buffer area as an empty tray.

6. The method according to claim 1, characterized in that, After the PLC determines that there are remaining goods after the target loose pallet is picked up, and controls the palletizing robot to enter a full dismantling mode to remove the remaining goods from the target loose pallet and complete the loose pallet reassembly task, the following steps are also included: The WCS triggers the writing operation of RFID tags on the target loose pallets that have completed the loose pallet reorganization task. The RFID tag information includes at least pallet identification, goods category, actual number of pieces stacked, and pallet reorganization timestamp. During the process of sending the target bulk pallet into the high-bay warehouse storage location, the WMS performs a secondary RFID reading and verification to compare whether the RFID tag information is consistent with the return information issued by the WCS. If they match, the WMS will be used to update the high-bay warehouse inventory ledger, deduct the original inventory record corresponding to the target loose pallet, and add the inventory record of the reorganized pallet, while simultaneously updating the warehouse capacity occupancy rate.

7. The method according to claim 1, characterized in that, The step of sending the outbound task message to the dedicated persistent queue of the corresponding scattered disk reassembly task in the message middleware via WMS includes: By adding a priority tag higher than that of a normal replenishment task to the outbound task message through WMS, the message middleware is instructed to store the outbound task message in a dedicated persistent queue and enable the consumption confirmation mechanism, and the outbound task message is delivered to the dedicated persistent queue.

8. An automatic reassembly system for bulk pallets in an elevated warehouse, characterized in that, The system includes: The Warehouse Management System (WMS) is used to acquire real-time inventory data of the high-bay warehouse, filter the real-time inventory data of the high-bay warehouse based on preset loose pallet judgment conditions to obtain a loose pallet list, and configure the loose pallet list based on preset outbound rules to obtain outbound task messages. WMS is used to send the outbound task message to the dedicated persistent queue of the corresponding loose pallet reorganization task in the message middleware, so that the warehouse control system WCS can subscribe to and pull the outbound task message. WCS is used to parse the outbound task message to obtain the task identifier, pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters corresponding to the loose pallet reassembly task. Based on the loose pallet identifier, target empty pallet identifier, target pallet stacking station and standard stacking parameters, stacker crane scheduling sub-tasks and robot scheduling sub-tasks bound to the task identifier are generated. The stacker crane scheduling sub-tasks and robot scheduling sub-tasks are written to the corresponding data blocks of the programmable logic controller (PLC) to obtain PLC execution instructions. The PLC is used to drive the palletizing robot to pick up goods from the target loose pallet corresponding to the loose pallet identifier and place them on the target empty pallet corresponding to the target empty pallet identifier according to the standard pallet type parameters at the target palletizing station. When it is determined that there are remaining goods after the target loose pallet is picked up, the PLC controls the palletizing robot to enter the full dismantling mode to remove the remaining goods from the target loose pallet, thereby realizing the loose pallet reorganization task.

9. An electronic device, characterized in that, The electronic device includes: At least one processor; and A memory communicatively connected to the at least one processor; wherein, The memory stores a computer program executable by the at least one processor, which enables the at least one processor to perform the automatic reorganization method for bulk pallets in elevated warehouses as described in any one of claims 1-7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions that, when executed by a processor, implement the automatic reorganization method for the bulk pallets in the high-bay warehouse as described in any one of claims 1-7.

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