Redundant automatic control system for three-dimensional storage

Abstract

The utility model relates to a redundant automatic control system for three-dimensional storage, and belongs to the technical field of three-dimensional storage warehouse automatic control. The control system comprises a plurality of controllers, a remote IO module, a plurality of frequency converter groups, a redundant dual-power switch and a field detection assembly. The field detection assembly is connected to an IO interface of the remote IO module; the plurality of frequency converter groups are cascaded; the plurality of controllers, the remote IO module and the last cascaded frequency converter group are all connected with the redundant dual-power switch, and the remote IO module is also connected with the first frequency converter group in the cascaded frequency converter groups. The problem that in the prior art, due to the fact that a certain control assembly of a three-dimensional warehouse breaks down, a warehouse-in and warehouse-out system of the three-dimensional warehouse breaks down is solved.

Description

Technical Field

[0001] The utility model relates to the technical field of automated control of stereoscopic warehouses, in particular to a redundant automated control system for stereoscopic warehouses. Background Art

[0002] With the rapid development of modern logistics, the automation and intelligence of warehousing systems are constantly improving. As a highly efficient space utilization and storage method, three-dimensional warehousing systems have been widely used. However, in some logistics fields with high efficiency requirements and high risk (such as flammable and explosive items), traditional three-dimensional warehousing systems have the risk of single points of failure during operation. Once a control node fails, it can paralyze the entire system, thereby affecting the operational efficiency and reliability of the warehousing system.

[0003] Conventional single controllers cannot fully meet the requirements of modern high-bay warehouse systems for efficient and reliable operation in the event of a failure or power outage. Therefore, developing a highly automated and reliable high-bay warehouse redundant control system to improve the efficiency and reliability of warehouse systems is of great practical significance and market demand. Utility Model Content

[0004] In view of the above analysis, the utility model aims to provide a redundant automation control system for three-dimensional warehousing, so as to solve the problem that the single controller of the existing three-dimensional warehousing system cannot fully meet the requirements of modern three-dimensional warehousing system for efficient and reliable operation when a failure or power outage occurs.

[0005] The purpose of this utility model is mainly achieved through the following technical solutions:

[0006] A redundant automation control system for three-dimensional warehousing, comprising multiple redundant controllers, a remote IO module, multiple redundant inverter groups, a redundant dual-power switch, and a field detection component; the field detection component is connected to the IO interface of the remote IO module; and multiple inverter groups are cascaded.

[0007] Multiple controllers, remote IO modules, and the last inverter group in the cascade are all connected to the redundant dual-power switch. The remote IO module is also connected to the first inverter group in the cascaded inverter groups.

[0008] Furthermore, the control system also includes multiple wireless AP devices and multiple four-way shuttle control modules. The number of the four-way shuttle control modules is the same as the number of wireless AP devices, and each four-way shuttle control module corresponds to a wireless AP device; the four-way shuttle control module is arranged in the four-way shuttle; each four-way shuttle control module is connected to the redundant dual-power switch through the corresponding wireless AP device.

[0009] Furthermore, each frequency converter group includes a layer-changing elevator frequency converter and a roller conveyor frequency converter; the layer-changing elevator frequency converter is connected to the layer-changing elevator motor; and the roller conveyor frequency converter is connected to the roller conveyor motor.

[0010] Furthermore, the on-site detection components include a roller cargo detection device, a shelf cargo position detection device, and a layer-changing elevator arrival detection device; the roller cargo detection device, the shelf cargo position detection device, and the layer-changing elevator arrival detection device are all connected to a redundant dual-power switch through a remote IO module, and then connected to multiple controllers through the redundant dual-power switch.

[0011] Furthermore, the on-site detection component also includes visual fault detection equipment; the visual fault detection equipment includes visible light monitoring equipment and infrared thermal imagers.

[0012] Furthermore, the roller conveyor cargo detection device, the shelf cargo position detection device, and the layer-changing elevator arrival detection device are all equipped with redundant RFID identification devices.

[0013] Furthermore, the control system also includes a power supply, which includes a first UPS power supply branch, a second UPS power supply branch, and a UPS power supply system bypass connected in parallel; the input ends of the first UPS power supply branch, the second UPS power supply branch, and the UPS power supply system bypass are all connected to the mains and the diesel generator set, and the output ends are used to output electrical energy to power the control system.

[0014] Furthermore, the control system also includes a frequency converter cabinet, a control cabinet and a network cabinet; each layer elevator frequency converter and roller conveyor frequency converter are respectively arranged in a frequency converter cabinet; the controller and remote IO module are located in the control cabinet; the redundant dual power supply switch and wireless AP device are located in the network cabinet.

[0015] Furthermore, the controller model is CPU 1517H-3PN.

[0016] Furthermore, the remote IO module model is ET 200MP.

[0017] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0018] 1. The redundant automated control system for the three-dimensional warehouse system of this utility model utilizes redundant controllers, redundant inverters, redundant dual-power switches, redundant four-way shuttle control modules, and power supplies including redundant UPS power branches. The on-site detection component utilizes a redundant detection method combining multiple visual fault detection devices and RFID recognition equipment. While the automated control system is operating, regardless of any failures in the level-changing elevator inverter, four-way shuttle control module, roller conveyor inverter, on-site detection components, wireless APs, controllers, network, or power supply, the three-dimensional warehouse system's redundant configuration can promptly maintain normal operation.

[0019] 2. The on-site detection components of the redundant automation control system of the three-dimensional warehouse of the utility model are connected to the redundant dual-power switch through the remote IO module, and then connected to multiple controllers through the redundant dual-power switch. At the same time, the remote IO module and the last inverter group of the cascade are connected to the redundant dual-power switch. Therefore, the controller, remote IO module, and inverter group are arranged on the ring network. When one of the devices fails, it will not affect the operation of its backup device, thus meeting the requirements of modern three-dimensional warehouse systems for efficient and reliable operation.

[0020] 3. The visual fault detection equipment of the present invention includes a visible light monitoring device and an infrared thermal imager. The visible light monitoring device can clearly confirm the details of the scene, and the infrared thermal imager can detect insufficient light or the temperature of the device. Therefore, they complement each other in visual fault detection and can detect the situation on the scene more accurately and comprehensively.

[0021] In the present invention, the above-mentioned technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of the present invention will be described in the following content, and some advantages will become apparent from the description or be understood through practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the text and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings are only used for the purpose of illustrating specific embodiments and are not to be considered as limiting the present invention. Throughout the accompanying drawings, the same reference symbols denote the same components.

[0023] Figure 1 Provide a structural diagram of a redundant automation control system for three-dimensional warehousing;

[0024] Figure 2 This is a schematic diagram of the connection relationship between the various components of a redundant automation control system for three-dimensional warehousing;

[0025] Figure 3This is a schematic diagram of the power supply composition of a redundant automation control system used in three-dimensional warehousing.

[0026] Reference numerals:

[0027] 1- Host computer;

[0028] 2-Controller;

[0029] 4-Synchronous fiber;

[0030] 6-Redundant dual power supply switch;

[0031] 7- Wireless AP equipment;

[0032] 9-Remote IO module;

[0033] 10-Inverter group;

[0034] 12- On-site detection components;

[0035] 13-power supply;

[0036] 15-mains electricity;

[0037] 16-diesel generator set;

[0038] 17-First UPS power supply branch;

[0039] 18- Second UPS power supply branch;

[0040] 20- Four-way shuttle control module. DETAILED DESCRIPTION

[0041] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, and are not used to limit the scope of the present invention.

[0042] A specific embodiment of the present invention discloses a redundant automation control system for three-dimensional warehousing, the structure of which is shown in the following diagram: Figure 1 shown.

[0043] The control system includes multiple redundant controllers 2, remote IO modules 9, multiple redundant inverter groups 10, redundant dual power switches 6 and field detection components 12; the field detection components 12 are connected to the IO interface of the remote IO module 9; the multiple inverter groups 10 are cascaded;

[0044] Multiple controllers 2 , remote IO modules 9 and the last cascaded inverter group 10 are all connected to the redundant dual-power switch 6 . The remote IO module 9 is also connected to the first inverter group 10 in the cascaded inverter groups 10 .

[0045] The connection relationship diagram of each component is as follows Figure 2 shown.

[0046] Controller 2 model is CPU 1517H-3PN.

[0047] Specifically, multiple controllers 2 can process the same project data and the same user program in parallel and are connected via a synchronous optical fiber 4. If one controller 2 fails, another controller 2 will take over control. The controllers 2 control the field detection components 12, the inverter group 10, and the four-way shuttle control module 20 via the ring network. When the controllers 2 receive and process the data reported by the field detection components 12, the inverter group 10, and the four-way shuttle control module 20, the data is collected by the host computer 1 via the ring network, forming a closed-loop control.

[0048] Each controller 2 is equipped with a hot standby redundant power supply, providing sufficient power to support simultaneous operation of two controllers 2. Each hot standby redundant power supply provides DC24V voltage to the controller 2. Each controller 2 is equipped with an AC380V to DC24V conversion power supply (i.e., a hot standby redundant power supply). If the conversion power supply of one controller 2 fails, the conversion power supply of the other controller can simultaneously provide conversion power to both controllers, ensuring normal power supply to the controllers 2. The stable operation of the controllers 2 ensures uninterrupted system operation, ensuring stable operation of the three-dimensional warehouse, and reducing unnecessary economic losses.

[0049] The redundant dual-power switch 6 supports MRP client and H-Sync forwarding functions. The wireless AP device 7 features high-performance wireless capabilities and supports IEEE 802.11ac Wave 2 technology, 2.4G and 5.8G dual-channel baseband. Multiple wireless AP devices 7 can operate simultaneously. The remote I / O module 9 is used to remotely collect data from the field detection component 12 and transmit control data from the controller 2 to the inverter group 10 and the four-way shuttle control module 20.

[0050] Multiple controllers 2 run logic control programs simultaneously and are connected to the PROFINET ring network. When any controller 2 fails or the PROFINET ring network is interrupted, remote data collection and control of the inverter group 10 and the four-way shuttle control module 20 are not affected.

[0051] The control system also includes multiple wireless AP devices 7 and multiple four-way shuttle control modules 20. The number of the four-way shuttle control modules 20 is the same as the number of the wireless AP devices 7, and each four-way shuttle control module 20 corresponds to a wireless AP device 7; the four-way shuttle control module 20 is arranged inside the four-way shuttle; each four-way shuttle control module 20 is connected to the redundant dual-power switch 6 through the corresponding wireless AP device 7.

[0052] Specifically, each floor of the three-dimensional warehouse is equipped with redundant four-way shuttle vehicles, and each vehicle is equipped with a four-way shuttle vehicle control module.

[0053] Each frequency converter group 10 includes a layer-changing elevator frequency converter and a roller conveyor frequency converter; the layer-changing elevator frequency converter is connected to the layer-changing elevator motor; and the roller conveyor frequency converter is connected to the roller conveyor motor.

[0054] Specifically, multiple layer-changing elevator inverters are independent of each other. When one of them fails, the inverter issues an alarm and the staff performs maintenance, while the other layer-changing elevator inverters operate normally. When one of the four-way shuttle control modules 20 or the four-way shuttle fails, the four-way shuttle control module 20 issues an alarm and sends location information to the controller 2. The controller 2 dispatches a four-way shuttle with normal function. The problem four-way shuttle exits the storage shelf and is sent to a designated location for manual maintenance. Multiple roller conveyors are driven by the roller conveyor inverters and operate independently and simultaneously. Under normal circumstances, multiple conveyor lines are used to operate in parallel. When one of them fails, the line operates normally and the transportation of goods is not interrupted.

[0055] The on-site detection component 12 includes a roller cargo detection device, a shelf cargo position detection device, and a layer-changing elevator arrival detection device; the roller cargo detection device, the shelf cargo position detection device, and the layer-changing elevator arrival detection device are all connected to the redundant dual-power switch 6 through the remote IO module 9, and then connected to multiple controllers 2 through the redundant dual-power switch 6.

[0056] The on-site detection component 12 also includes a visual fault detection device; the visual fault detection device includes a visible light monitoring device and an infrared thermal imager.

[0057] The roller cargo detection device, shelf cargo position detection device, and layer elevator arrival detection device are all equipped with redundant RFID identification equipment.

[0058] Specifically, to improve on-site detection accuracy and system stability, redundant sensors, such as redundant motor temperature sensors and collision limit switches, are installed on-site. This configuration reduces the number of false feedbacks from the system in the event of a sensor failure, further ensuring system stability. These redundant sensors can monitor field data in real time, making feedback signals more reliable and stable, enabling the control system to operate more accurately and efficiently. This redundant control significantly reduces the economic losses caused by equipment failure, ensuring a safe and reliable control process.

[0059] The on-site detection component 12 includes a roller conveyor cargo detection device, a shelf cargo position detection device, a level-changing elevator arrival detection device, and visual fault detection equipment. Redundant RFID identification devices are installed on the roller conveyor cargo detection device, the level-changing elevator arrival detection devices on each floor, and the shelf cargo position detection devices. Redundant sensors, such as photoelectric limit switches and wireless temperature sensors, are also installed on-site. For example, when a level-changing elevator arrives, it needs to strike a photoelectric limit switch and provide a feedback signal. The on-site detection component 12 and the redundant sensors transmit information to the controller 2, which processes it and controls the level-changing elevator inverter, the roller conveyor inverter, and the four-way shuttle control module 20, achieving closed-loop control of the equipment. Visual fault detection equipment is also installed on-site to detect and issue an alarm if the four-way shuttle accidentally hits or if cargo falls and damages the vehicle. The on-site detection component 12 and the redundant sensors are not a single entity but are organically connected to the inverter assembly 10 and the four-way shuttle control module 20, ensuring efficient and stable operation of the redundant equipment.

[0060] A level-changing elevator is located at the entrance and exit of the three-dimensional warehouse. Four shuttles are located inside the shelves, which have running tracks for loading and unloading goods. Pallets are RFID-tagged. The warehousing process is as follows: the RFID information of the goods is detected, the host computer 1 records the goods information, and the controller 2 plans the storage location based on the RFID information. The planned storage location first selects an empty space that has previously stored the same item. If it is a new item, a new space is reserved and the RFID tag of the pallet in the empty space is bound to the item. The goods enter the roller conveyor. The RFID identification device of the roller conveyor's cargo detection device detects the goods and transports them to the storage entrance. At the same time, controller 2 controls the level change elevator to reach the first floor. The RFID identification device of the level change elevator's in-place detection device detects the goods. The forklift moves the goods from the roller conveyor to the level change elevator. The RFID identification device of the level change elevator's in-place detection device detects the goods. The elevator rises to the designated level. The RFID identification device of the in-place detection device detects the goods and the forklift moves the goods to the four-way shuttle. The four-way shuttle transports the goods to the designated shelf location. The RFID identification device of the shelf location detection device detects the goods. The RFID identification device is connected to controller 2 and host computer 1. Controller 2 records the completion of this entry and proceeds with the entry plan for the next goods. Host computer 1 records the location of the goods entering the warehouse. The reverse process is used for outbound delivery. Redundant copies of the on-site detection components 12 and sensors are set to prevent damage from affecting equipment operation.

[0061] The power supply 13 is shown in the schematic diagram. Figure 3 shown.

[0062] The control system also includes a power supply 13, which includes a first UPS power supply branch 17, a second UPS power supply branch 18, and a UPS power supply system bypass connected in parallel; the input ends of the first UPS power supply branch 17, the second UPS power supply branch 18, and the UPS power supply system bypass are all connected to the mains 15 and the diesel generator set 16, and the output ends are used to output electrical energy to power the control system.

[0063] Specifically, in an emergency, the redundant UPS system can simultaneously power power loads such as the on-site three-dimensional storage controller 2, the redundant dual-power switch 6, the on-site detection component 12, the inverter group 10, and the four-way shuttle control module 20. During normal operation, the power supply system is provided by 380V AC mains 15, which is bypassed by the UPS power supply system to reach the power loads. When the mains 15 fails, it switches to the diesel generator set 16 or the UPS power supply branch for power supply. Due to the large number of three-dimensional storage power loads, the first UPS power supply branch 17 and the second UPS power supply branch 18 can operate simultaneously to provide power. The UPS unit dynamically calculates the remaining power and activates the diesel generator set 16 when the power is insufficient to ensure normal operation of the system.

[0064] The first and second UPS power supply branches 18 each include an AC / DC module and a DC / AC module connected in series, along with a battery pack. The battery pack's charging port is connected to the AC / DC module's output, which in turn is connected to the DC / AC module's input. This provides power to the load in the absence of mains power 15. The diesel generator set 16 is a DC generator with a commutator and an output voltage of 110V AC. The 100KVA battery pack can provide system power during a power outage.

[0065] The control system also includes a frequency converter cabinet, a control cabinet and a network cabinet; each layer elevator frequency converter and roller conveyor frequency converter are respectively arranged in a frequency converter cabinet; the controller 2 and remote IO module 9 are located in the control cabinet; the redundant dual power switch 6 and wireless AP device 7 are located in the network cabinet.

[0066] Specifically, the control system uses multiple control cabinets, with high voltage and low voltage located in different cabinets; high-frequency equipment is located separately in different cabinets to avoid electromagnetic interference.

[0067] The remote IO module 9 is of model ET 200MP.

[0068] Specifically, the remote IO module 9 receives the digital signal from the field detection component 12 and is connected to the redundant dual-power switch 6 through the network port.

[0069] The control system includes a redundant host computer 1 ; each host computer 1 is connected to the redundant dual-power switch 6 .

[0070] Specifically, the system includes at least two host computers 1, each with an operating screen displaying on-site operational information and providing timely alarms in the event of a fault, forming a closed-loop control system. Host computer 1 includes dual Ethernet communication network cards, enabling immediate switching to a backup card in the event of a network failure without disrupting normal system operation. Host computer 1 is connected to the on-site detection component 12, the four-way shuttle control module 20, the inverter group 10, and the redundant dual-power switch 6 to collect on-site information, which is then issued by the operator. Host computer 1 utilizes a redundant hard drive configuration to ensure normal operation even in the event of computer damage.

[0071] Compared to the existing technology, the redundant automated control system for three-dimensional storage provided in this embodiment utilizes a redundant controller 2, redundant inverter groups 10, redundant dual-power switches 6, redundant four-way shuttle control modules 20, and a power supply 13 including redundant UPS power branches. The on-site detection component 12 utilizes a redundant detection method that combines multiple visual fault detection devices with RFID recognition devices. While the automated control system is operating, regardless of any failures in the level-changing elevator inverter, four-way shuttle control module 20, roller conveyor inverter, on-site detection component 12, wireless AP device 7, controller 2, network, or power supply 13, the redundant control system for three-dimensional storage can utilize its redundant configuration to promptly maintain normal system operation. The field detection component 12 of the redundant automation control system for the three-dimensional warehouse provided in this embodiment is connected to the redundant dual-power switch 6 through the remote IO module 9, and then connected to multiple controllers 2 through the redundant dual-power switch 6. At the same time, the remote IO module 9 and the last inverter group 10 of the cascade are all connected to the redundant dual-power switch 6. Therefore, the controller 2, the remote IO module 9, and the inverter group 10 are arranged on the ring network. When one of the devices fails, it will not affect the operation of its backup device, thus meeting the requirements of modern three-dimensional warehouse systems for efficient and reliable operation. The visual fault detection equipment provided in this embodiment includes a visible light monitoring device and an infrared thermal imager. The visible light monitoring device can clearly confirm the details of the scene, and the infrared thermal imager can detect insufficient light or the temperature of the motor. Therefore, they complement each other in terms of visual fault detection and can more accurately and comprehensively detect the situation on the scene.

[0072] Those skilled in the art will appreciate that the programs / software involved in the above embodiments are common methods in the prior art, and the present invention does not involve any software improvements. The present invention merely requires connecting the various devices with corresponding functions through the connection relationships provided in the embodiments of the present invention, and does not involve any program or software improvements. As for the connection methods between the various hardware devices with corresponding functions, these can be implemented by those skilled in the art using existing technologies and will not be described in detail here.

[0073] The above is only a preferred specific implementation method of the present invention, but the protection scope of the present invention is not limited to this. Any changes or replacements that can be easily thought of by any technician familiar with this technical field within the technical scope disclosed in the present invention should be covered by the protection scope of the present invention.

Claims

1. A redundant automation control system for three-dimensional warehousing, characterized in that: The control system includes multiple redundant controllers, remote IO modules, multiple redundant inverter groups, redundant dual-power switches and field detection components; the field detection components are connected to the IO interface of the remote IO module; multiple inverter groups are cascaded; Multiple controllers, remote IO modules, and the last inverter group in the cascade are all connected to the redundant dual-power switch. The remote IO module is also connected to the first inverter group in the cascaded inverter groups.

2. The redundant automation control system according to claim 1, characterized in that: The control system also includes multiple wireless AP devices and multiple four-way shuttle control modules. The number of the four-way shuttle control modules is the same as the number of wireless AP devices, and each four-way shuttle control module corresponds to a wireless AP device; the four-way shuttle control module is arranged inside the four-way shuttle; each four-way shuttle control module is connected to the redundant dual-power switch through the corresponding wireless AP device.

3. The redundant automation control system according to claim 2, characterized in that: Each frequency converter group includes a layer-changing elevator frequency converter and a roller conveyor frequency converter; the layer-changing elevator frequency converter is connected to the layer-changing elevator motor; and the roller conveyor frequency converter is connected to the roller conveyor motor.

4. The redundant automation control system according to claim 3, characterized in that: The on-site detection components include a roller cargo detection device, a shelf cargo position detection device, and a layer elevator arrival detection device; the roller cargo detection device, the shelf cargo position detection device, and the layer elevator arrival detection device are all connected to a redundant dual-power switch through a remote IO module, and then connected to multiple controllers through the redundant dual-power switch.

5. The redundant automation control system according to claim 4, characterized in that: The on-site detection components also include visual fault detection equipment; the visual fault detection equipment includes visible light monitoring equipment and infrared thermal imagers.

6. The redundant automation control system according to claim 4, characterized in that: The roller cargo detection device, shelf cargo position detection device, and layer elevator arrival detection device are all equipped with redundant RFID identification equipment.

7. The redundant automation control system according to claim 1, characterized in that: The control system also includes a power supply, which includes a first UPS power supply branch, a second UPS power supply branch, and a UPS power supply system bypass connected in parallel; the input ends of the first UPS power supply branch, the second UPS power supply branch, and the UPS power supply system bypass are all connected to the mains and the diesel generator set, and the output ends are used to output electrical energy to power the control system.

8. The redundant automation control system according to claim 3, characterized in that: The control system also includes a frequency converter cabinet, a control cabinet and a network cabinet; each layer elevator frequency converter and roller conveyor frequency converter are respectively arranged in a frequency converter cabinet; the controller and remote IO module are located in the control cabinet; the redundant dual power switch and wireless AP device are located in the network cabinet.

9. The redundant automation control system according to claim 1, characterized in that: The controller model is CPU 1517H-3PN.

10. The redundant automation control system according to claim 1, characterized in that: The remote IO module model is ET200MP.

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