Intelligent stereoscopic warehouse with redundancy automatic control function

Abstract

The utility model relates to an intelligent stereoscopic warehouse with a redundant automatic control function. The intelligent stereoscopic warehouse comprises a stereoscopic warehouse body, redundant goods conveying equipment and detection and control network equipment, the goods conveying equipment comprises a roller way conveyor, a layer changing elevator and a four-way shuttle vehicle; the roller conveyor is located outside a warehouse-in and warehouse-out opening of the stereoscopic warehouse. The layer changing elevator is located at a warehouse-in and warehouse-out opening of the stereoscopic warehouse. The four-way shuttle vehicle is located in the stereoscopic warehouse; the detection and control network equipment comprises a redundant dual-power switch, a plurality of redundant controllers, a plurality of redundant frequency converter groups and a four-way shuttle vehicle control module; the controller, the frequency converter group and the four-way shuttle vehicle control module are connected with the redundant dual-power switch; each frequency converter group comprises a roller conveyor frequency converter and a layer changing elevator frequency converter; the roller conveyor frequency converter is connected with a motor of the roller conveyor; the layer-changing elevator frequency converter is connected with a motor of the layer-changing elevator; and the four-way shuttle vehicle control module is used for controlling the four-way shuttle vehicle.

Description

Technical Field

[0001] The utility model relates to the technical field of automated stereoscopic warehouses, in particular to an intelligent stereoscopic warehouse with redundant automated control functions. 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 and single power supplies 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 to improve the efficiency and reliability of the warehouse system is of great practical significance and market demand. Utility Model Content

[0004] In view of the above analysis, the utility model aims to provide an intelligent three-dimensional warehouse with redundant automatic control function to solve the problem that the existing ordinary single-controller, single-power supply intelligent three-dimensional warehouse is prone to paralysis of the warehousing and outgoing system when a single device fails or shuts down or loses power.

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

[0006] An intelligent high-bay warehouse with redundant automatic control function, comprising a high-bay warehouse body, redundant cargo conveying equipment, and detection and control network equipment;

[0007] Cargo conveying equipment includes roller conveyors, layer-changing elevators, and four-way shuttles;

[0008] The roller conveyor is located outside the entrance and exit of the three-dimensional warehouse; the layer-changing elevator is located at the entrance and exit of the three-dimensional warehouse; the four-way shuttle is located inside the three-dimensional warehouse, and redundant four-way shuttles are installed on each floor of the warehouse;

[0009] The detection and control network equipment includes a redundant dual-power switch, multiple redundant controllers, multiple redundant inverter groups, and a four-way shuttle control module; the multiple controllers, multiple inverter groups, and four-way shuttle control module are all connected to the redundant dual-power switch;

[0010] Each inverter group includes a roller conveyor inverter and a layer-changing elevator inverter; the roller conveyor inverter is connected to the motor of the roller conveyor; the layer-changing elevator inverter is connected to the motor of the layer-changing elevator;

[0011] The four-way shuttle control module is used to control the four-way shuttle.

[0012] Furthermore, the cargo conveying equipment also includes redundant stackers; a fixed bracket is provided on the ground of each floor of the three-dimensional warehouse; a horizontal guide rail is arranged on the bracket, and a vertical guide rail is provided on the horizontal guide rail, and the vertical guide rail runs through each floor of the three-dimensional warehouse; the stacker is configured to move on the horizontal guide rail and the vertical guide rail; pulleys are provided on the bottom and side of the stacker.

[0013] Furthermore, the stacker also includes a JAKA robotic arm, at the end of which a gripper and an RFID identification device are provided. The gripper is used to move goods between the four-way shuttle and the warehouse shelves; the RFID identification device is used to identify labels on the goods.

[0014] Furthermore, the stacker also includes a stacker motor, a stacker frequency converter, a stacker motor encoder, and a stacker controller; the stacker motor includes a lifting motor, a horizontal motor, and a fork motor; the lifting motor and the horizontal motor are used to drive the stacker to move on the vertical guide rail and the horizontal guide rail respectively; the fork motor is used to control the movement of the JAKA robotic arm; the stacker frequency converter is connected to the fork motor for adjusting the speed of the fork motor; one end of the stacker motor encoder is connected to the stacker motor, and the other end is connected to the stacker controller.

[0015] Furthermore, a pan-tilt platform is installed on the top of the four-way shuttle vehicle; a visual fault detection device is provided on the pan-tilt platform; the visual fault detection device includes a visible light monitoring device and an infrared thermal imager.

[0016] Furthermore, the detection and control network equipment also includes a remote IO module and an on-site detection component; the on-site detection component 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 a redundant dual-power switch through a remote IO module, and then connected to multiple redundant controllers through the redundant dual-power switch.

[0017] Furthermore, the on-site detection component also includes a motor temperature sensor and a collision limit switch; the motor temperature sensor is located on the motors of the layer-changing elevator, roller conveyor, and stacker, and each motor is equipped with a redundant motor temperature sensor;

[0018] The collision limit switches are respectively arranged at the starting and end points of the roller conveyor, the limit points of the layer-changing elevator at the entrance and exit of each floor, the starting and end points of the four-way shuttle running track, and the starting and end points of the vertical and horizontal guide rails of the stacker; each limit point is provided with a redundant collision limit switch.

[0019] Furthermore, the detection and control network equipment also includes multiple wireless AP devices; each four-way shuttle control module and each stacker controller are connected to the wireless AP device; the wireless AP device is connected to the redundant dual-power switch.

[0020] Furthermore, the intelligent high-bay warehouse includes redundant host computers; each host computer has built-in dual Ethernet communication network cards and redundant hard disks; the host computer is connected to the on-site detection components, multiple redundant controllers, four-way shuttle control modules, stacker controllers, and inverter groups through redundant dual-power switches.

[0021] Furthermore, the high-bay warehouse also includes a frequency converter cabinet, a control cabinet, a network cabinet and an operation room; 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; and the host computer is located in the operation room.

[0022] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0023] 1. The intelligent high-bay warehouse of this utility model utilizes redundant cargo conveying equipment, redundant detection and control network equipment, and redundant power supplies. During operation, regardless of any failures in the level-changing elevator inverter, four-way shuttle control module, roller conveyor inverter, field detection components, wireless AP equipment, controller, network, or power supply, the intelligent high-bay warehouse can maintain normal operation using its redundant configuration.

[0024] 2. The on-site detection components of the intelligent high-bay warehouse of the present invention 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 any one of the devices fails, it will not affect the operation of its backup device, thus meeting the needs of modern intelligent high-bay warehouses for efficient and reliable operation.

[0025] 3. The visual fault detection equipment of the present invention includes a visible light monitoring device and an infrared thermal imager installed on a pan-tilt head. The rotation of the pan-tilt head drives the visible light monitoring device and the infrared thermal imager to detect in all directions; 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.

[0026] 4. The utility model's roller cargo detection device, shelf cargo position detection device, layer-changing elevator arrival detection device, and stacker JAKA robotic arm end are all equipped with redundant RFID identification devices; after the RFID identification device identifies the cargo information, it transmits the cargo information to the controller, and the controller arranges the cargo position shelf for the cargo; the layer-changing elevator lifts the cargo to the corresponding layer, and the four-way shuttle transports the cargo to the designated shelf. The stacker and the four-way shuttle are located on different tracks and cooperate with each other. The stacker moves the cargo from the four-way shuttle to the designated shelf cargo position; the opposite is true when leaving the warehouse, realizing a fully automated in and out warehouse system.

[0027] 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

[0028] 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.

[0029] Figure 1 Provide a block diagram for an intelligent high-bay warehouse with redundant automated control functions;

[0030] Figure 2 This is a schematic diagram of the ring network connection of detection and control network equipment for an intelligent three-dimensional warehouse with redundant automated control functions;

[0031] Figure 3 This is a schematic diagram of the power supply composition of an intelligent high-bay warehouse with redundant automated control functions.

[0032] Reference numerals:

[0033] 1- Host computer;

[0034] 2-Controller;

[0035] 4-Synchronous fiber;

[0036] 6-Redundant dual power supply switch;

[0037] 7- Wireless AP equipment;

[0038] 9-Remote IO module;

[0039] 10- inverter group 10;

[0040] 12- On-site detection components;

[0041] 13-power supply;

[0042] 15-mains electricity;

[0043] 16-diesel generator set;

[0044] 17-First UPS power supply branch;

[0045] 18- Second UPS power supply branch;

[0046] 20- Four-way shuttle control module;

[0047] 21-layer-changing elevator;

[0048] 22- Roller conveyor;

[0049] 23- Four-way shuttle. DETAILED DESCRIPTION

[0050] 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.

[0051] A specific embodiment of the present utility model discloses an intelligent three-dimensional warehouse with redundant automatic control function, such as Figure 1 shown.

[0052] The intelligent three-dimensional warehouse includes a three-dimensional warehouse body, redundant cargo conveying equipment, and detection and control network equipment;

[0053] The cargo conveying equipment includes a roller conveyor 22, a layer-changing elevator 21, and a four-way shuttle 23;

[0054] The roller conveyor 22 is located outside the entrance and exit of the three-dimensional warehouse; the layer-changing elevator 21 is located at the entrance and exit of the three-dimensional warehouse; the four-way shuttle 23 is located inside the three-dimensional warehouse, and redundant four-way shuttles 23 are set up on each floor of the warehouse;

[0055] The detection and control network equipment includes a redundant dual-power switch 6, multiple redundant controllers 2, multiple redundant inverter groups 10, and a four-way shuttle control module 20; multiple controllers 2, multiple inverter groups 10, and the four-way shuttle control module 20 are all connected to the redundant dual-power switch 6;

[0056] Each inverter group 10 includes an inverter for the roller conveyor 22 and an inverter for the layer-changing elevator 21; the inverter for the roller conveyor 22 is connected to the motor of the roller conveyor 22; the inverter for the layer-changing elevator 21 is connected to the motor of the layer-changing elevator 21;

[0057] The four-way shuttle control module 20 is used to control the four-way shuttle 23 .

[0058] Specifically, the three-dimensional warehouse body uses shelves that are several, dozens, or even dozens of layers high to store unit cargo. Each layer can be equipped with multiple rows of shelves, and partitions (i.e., floors) are installed between adjacent layers. The three-dimensional warehouse body is equipped with an entrance and exit. Roller conveyors 22 are located outside the entrance and exit of the three-dimensional warehouse, used to transport goods from the outside to the entrance and exit of the three-dimensional warehouse. The entrance and exit are equipped with redundant level-changing elevators 21. When a level-changing elevator 21 fails, the faulty level-changing elevator 21 exits the entrance and exit of the three-dimensional warehouse and is replaced by a new level-changing elevator 21. Two parallel horizontal guide rails are set on the partition from the entrance to the shelf, one of which is equipped with a four-way shuttle 23; the other is equipped with a stacker; the roller conveyor 22 is located outside the main body of the three-dimensional warehouse and is used to transport goods to the entrance and exit. The layer elevator 21 transports the goods to the four-way shuttle 23 on each floor. The four-way shuttle 23 transports the goods to the designated shelf, and the stacker moves the goods from the four-way shuttle 23 to the shelf position.

[0059] Detection and control network equipment ring network connection diagram as follows Figure 2 shown.

[0060] Specifically, multiple inverter groups 10 are cascaded; multiple controllers 2, remote IO modules 9 and the last inverter group 10 of the cascade are all connected to the redundant dual power switch 6, and the remote IO module 9 is also connected to the first inverter group 10 in the cascaded inverter group 10.

[0061] Multiple controllers 2 can process the same project data and the same user program in parallel and are connected via 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 through 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 through the ring network, forming a closed-loop control.

[0062] Controller 2 model is CPU 1517H-3PN.

[0063] 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 2 can simultaneously provide conversion power to both controllers 2, ensuring normal power supply to the controllers 2. The stable operation of the controllers 2 ensures uninterrupted system operation, ensuring stable operation of the intelligent warehouse and reducing unnecessary economic losses.

[0064] 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.

[0065] 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.

[0066] The frequency converters of multiple layer-changing elevators 21 are independent of each other. When one of them fails, the frequency converter will issue an alarm and the staff will carry out maintenance. The frequency converters of the other layer-changing elevators 21 will operate normally. When one of the four-way shuttle control modules 20 or the four-way shuttle 23 fails, the four-way shuttle control module 20 will issue an alarm and send location information to the controller 2. The controller 2 will dispatch a four-way shuttle 23 with normal function. The problem four-way shuttle 23 will exit the three-dimensional warehouse shelf and be sent to the designated location for manual maintenance. Multiple roller conveyors 22 are driven by the frequency converters of the roller conveyors 22 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.

[0067] The cargo conveying equipment also includes redundant stackers; a fixed bracket is provided on the ground of each floor of the three-dimensional warehouse; a horizontal guide rail is arranged on the bracket, and a vertical guide rail is provided on the horizontal guide rail, and the vertical guide rail runs through each floor of the three-dimensional warehouse; the stacker is configured to move on the horizontal guide rail and the vertical guide rail; pulleys are provided at the bottom and side of the stacker.

[0068] Specifically, each floor of the three-dimensional warehouse is equipped with a stacker, which can also change floors. When a stacker needs to change floors, it moves to the target floor via vertical guide rails and then moves along the target floor's horizontal guide rails to the vicinity of the four-way shuttle 23 on the target floor. If a floor is heavy with cargo or a stacker malfunctions, a stacker on another floor can move via vertical guide rails to the floor with the heavy cargo or malfunction, and then move the cargo from the four-way shuttle 23 on that floor to the shelf storage space, thus accelerating the cargo handling process.

[0069] The stacker also includes a JAKA robotic arm, at the end of which a gripper and an RFID identification device are provided. The gripper is used to move goods between the four-way shuttle 23 and the warehouse shelves; the RFID identification device is used to identify labels on the goods.

[0070] Specifically, the JAKA robotic arm has a telescopic range of about 2 meters and needs to work in conjunction with the four-way shuttle 23. The end of the JAKA robotic arm is equipped with an RFID recognition device. After identifying the label of the goods, it compares it with the label of the pallet on the shelf. If the label information matches, the goods are moved from the four-way shuttle 23 to the shelf.

[0071] The stacker also includes a stacker motor, a stacker frequency converter, a stacker motor encoder, and a stacker controller 2; the stacker motor includes a lifting motor, a horizontal motor, and a fork motor; the lifting motor and the horizontal motor are used to drive the stacker to move on the vertical guide rail and the horizontal guide rail respectively; the fork motor is used to control the movement of the JAKA robotic arm; the stacker frequency converter is connected to the fork motor for adjusting the speed of the fork motor; one end of the stacker motor encoder is connected to the stacker motor, and the other end is connected to the stacker controller 2.

[0072] A pan-tilt platform is installed on the top of the four-way shuttle 23; a visual fault detection device is provided on the pan-tilt platform; the visual fault detection device includes a visible light monitoring device and an infrared thermal imager.

[0073] Specifically, a pan-tilt platform is provided on the four-way shuttle 23 on each floor. The pan-tilt platform can drive the visible light monitoring equipment and the infrared thermal imager to move through horizontal rotation and pitch movement, so as to detect in all directions; the visible light monitoring equipment can clearly confirm the details of the scene, and the infrared thermal imager can detect insufficient light or the temperature of the device, thus forming a complementary role in visual fault detection and being able to detect the situation on site more accurately and comprehensively.

[0074] The detection and control network equipment also includes a remote IO module 9 and an on-site detection component 12; the on-site detection component 12 includes a roller cargo detection device, a shelf cargo position detection device, and a layer-changing elevator 21 arrival detection device; the roller cargo detection device, the shelf cargo position detection device, and the layer-changing elevator 21 arrival detection device are all connected to the redundant dual-power switch 6 through the remote IO module 9, and then connected to multiple redundant controllers 2 through the redundant dual-power switch 6.

[0075] The remote IO module 9 is of model ET 200MP.

[0076] 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.

[0077] The roller cargo detection device, the shelf cargo position detection device, and the layer-changing elevator 21 arrival detection device are all equipped with redundant RFID identification equipment.

[0078] Specifically, when goods are put into storage, the RFID identification device detects the RFID information of the goods, the upper computer 1 records the goods information, and the controller 2 plans the storage location according to the RFID information. The planned storage location will first choose the empty space where the item was previously stored. If it is a new type of item, a reserved space will be set up again, and the RFID tag of the pallet in the empty space will be bound to the goods of this type. When 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. Simultaneously, controller 2 controls the level-changing elevator 21 to reach the first floor. The RFID identification device of the level-changing elevator 21 detects the goods and the forklift moves the goods from the roller conveyor to the level-changing elevator 21. The RFID identification device of the level-changing elevator 21's ...

[0079] The field detection component 12 also includes a motor temperature sensor and a collision limit switch; the motor temperature sensor is located on the motors of the layer elevator 21, the roller conveyor 22, and the stacker, and each motor is equipped with a redundant motor temperature sensor;

[0080] The collision limit switches are respectively arranged at the starting and end points of the roller conveyor, the limit points of the layer-changing elevator 21 at the entrance and exit of each floor, the starting and end points of the running track of the four-way shuttle 23, and the starting and end points of the vertical and horizontal guide rails of the stacker; each limit point is provided with a redundant collision limit switch.

[0081] 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.

[0082] Redundant sensors, such as photoelectric limit switches and wireless temperature sensors, are also installed on site. These sensors are redundantly installed. For example, when the floor-changing elevator 21 is in place, it needs to collide with the photoelectric limit switch and provide a feedback signal. The on-site detection component 12 and redundant sensors transmit information to the controller 2, which then processes and controls the inverter for the floor-changing elevator 21, the inverter for the roller conveyor 22, and the four-way shuttle control module 20, achieving closed-loop control of the equipment. Visual fault detection equipment is also installed on site. This equipment can detect and issue an alarm if the four-way shuttle 23 experiences an unexpected collision or if cargo falls and is damaged. The on-site detection component 12 and redundant sensors are not a single entity, but rather form an organic connection with the inverter group 10 and the four-way shuttle control module 20, enabling efficient and stable operation of the redundant equipment.

[0083] The detection and control network equipment also includes multiple wireless AP devices 7; each four-way shuttle control module 20 and each stacker controller 2 are connected to the wireless AP device 7; the wireless AP device 7 is connected to the redundant dual-power switch 6.

[0084] Specifically, the four-way shuttle control module 20 is arranged in the four-way shuttle 23; the stacker controller 2 is arranged in the stacker; each four-way shuttle control module 20 and the stacker controller 2 are connected to the redundant dual-power switch 6 through the corresponding wireless AP device 7, and the four-way shuttle control module 20 and the stacker controller 2 can upload data to the controller 2, and then upload it to the host computer 1; the four-way shuttle control module 20 and the stacker controller 2 can also be controlled by the controller 2.

[0085] The intelligent high-bay warehouse includes a redundant host computer 1; each host computer 1 has built-in dual Ethernet communication network cards and redundant hard disks; the host computer 1 is connected to the on-site detection component 12, multiple redundant controllers 2, a four-way shuttle control module 20, a stacker controller 2, and a frequency converter group 10 through a redundant dual-power switch 6.

[0086] The intelligent high-bay warehouse also includes a frequency converter cabinet, a control cabinet, a network cabinet and an operation room; the frequency converter of each layer elevator 21 and the frequency converter of the roller conveyor 22 are respectively arranged in a frequency converter cabinet; the controller 2 and the remote IO module 9 are located in the control cabinet; the redundant dual-power switch 6 and the wireless AP device 7 are located in the network cabinet; and the host computer 1 is located in the operation room.

[0087] 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.

[0088] The intelligent high-bay warehouse consists of 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 computers 1 have dual built-in Ethernet communication network cards, enabling immediate switching to a backup card in the event of a network failure without disrupting normal system operation. Host computers 1 are 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 computers 1 utilize redundant hard drives to ensure normal operation even in the event of computer damage.

[0089] The power supply 13 is shown in the figure. Figure 3 shown.

[0090] The intelligent high-bay warehouse 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.

[0091] Specifically, in an emergency, the redundant UPS system can simultaneously power loads such as cargo handling equipment, controller 2, redundant dual-power switch 6, field detection component 12, inverter group 10, and 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, power is switched to the diesel generator set 16 or the UPS power branch. Due to the large number of power loads in the high-bay warehouse, the first UPS power branch 17 and the second UPS power 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.

[0092] The first and second UPS power supply branches 18 each include an AC / DC module and a DC / AC module connected in series. The battery pack charging port is connected to the AC / DC module output, which in turn is connected to the DC / AC module 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.

[0093] Compared to the prior art, the intelligent high-bay warehouse provided in this embodiment utilizes redundant cargo conveying equipment, redundant detection and control network equipment, and redundant power supply 13. During operation, regardless of any failures in the level change elevator 21 inverter, the four-way shuttle control module 20, the roller conveyor 22 inverter, the field detection component 12, the wireless AP device 7, the controller 2, the network, or the power supply 13, the intelligent high-bay warehouse can maintain normal operation using its redundant configuration. The field detection component 12 of the intelligent high-bay warehouse provided in this embodiment is connected to a redundant dual-power switch 6 via a remote IO module 9, which in turn is connected to multiple controllers 2 via the redundant dual-power switch 6. Simultaneously, the remote IO module 9 and the last inverter group 10 in the cascade are all connected to the redundant dual-power switch 6. Therefore, the controller 2, remote IO module 9, and inverter group 10 are arranged on a ring network. Failure of any one of these devices will not affect the operation of the backup device, thus meeting the requirements of modern intelligent high-bay warehouses for efficient and reliable operation. The visual fault detection device provided in this embodiment includes a visible light monitoring device and an infrared thermal imager mounted on a pan-tilt platform. The rotation of the pan-tilt platform drives the visible light monitoring device and the infrared thermal imager to detect various directions. 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 more accurately and comprehensively detect the situation on the scene. The roller cargo detection device, shelf storage location detection device, layer change elevator 21 in-place detection device, and stacker JAKA robot arm end provided in this embodiment are all equipped with redundant RFID identification devices. After the RFID identification device identifies the cargo information, it transmits the cargo information to the controller 2, which arranges the cargo location and shelf. The layer change elevator 21 lifts the cargo to the corresponding level, and the four-way shuttle 23 transports the cargo to the designated shelf. The stacker and four-way shuttle 23 are located on different tracks and cooperate with each other. The stacker moves the cargo from the four-way shuttle 23 to the designated shelf location. The opposite process occurs during outbound transportation, realizing a fully automated inbound and outbound system.

[0094] 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.

[0095] 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. An intelligent three-dimensional warehouse with redundant automatic control function, characterized in that: The intelligent three-dimensional warehouse includes a three-dimensional warehouse body, redundant cargo conveying equipment, and detection and control network equipment; Cargo conveying equipment includes roller conveyors, layer-changing elevators, and four-way shuttles; The roller conveyor is located outside the entrance and exit of the three-dimensional warehouse; the layer-changing elevator is located at the entrance and exit of the three-dimensional warehouse; the four-way shuttle is located inside the three-dimensional warehouse, and redundant four-way shuttles are installed on each floor of the warehouse; The detection and control network equipment includes a redundant dual-power switch, multiple redundant controllers, multiple redundant inverter groups, and a four-way shuttle control module; the multiple controllers, multiple inverter groups, and four-way shuttle control module are all connected to the redundant dual-power switch; Each inverter group includes a roller conveyor inverter and a layer-changing elevator inverter; the roller conveyor inverter is connected to the motor of the roller conveyor; the layer-changing elevator inverter is connected to the motor of the layer-changing elevator; The four-way shuttle control module is used to control the four-way shuttle.

2. The intelligent high-bay warehouse according to claim 1, characterized in that: The cargo conveying equipment also includes redundant stackers; a fixed bracket is provided on the ground of each floor of the three-dimensional warehouse; a horizontal guide rail is arranged on the bracket, and a vertical guide rail is provided on the horizontal guide rail, and the vertical guide rail runs through each floor of the three-dimensional warehouse; the stacker is configured to move on the horizontal guide rail and the vertical guide rail; pulleys are provided at the bottom and side of the stacker.

3. The intelligent high-bay warehouse according to claim 2, characterized in that: The stacker also includes a JAKA robotic arm, at the end of which a gripper and an RFID identification device are provided. The gripper is used to move goods between the four-way shuttle and the warehouse shelves; the RFID identification device is used to identify the labels on the goods.

4. The intelligent high-bay warehouse according to claim 3, characterized in that: The stacker also includes a stacker motor, a stacker frequency converter, a stacker motor encoder, and a stacker controller; the stacker motor includes a lifting motor, a horizontal motor, and a fork motor; the lifting motor and the horizontal motor are used to drive the stacker to move on the vertical guide rail and the horizontal guide rail respectively; the fork motor is used to control the movement of the JAKA robotic arm; the stacker frequency converter is connected to the fork motor for adjusting the speed of the fork motor; one end of the stacker motor encoder is connected to the stacker motor, and the other end is connected to the stacker controller.

5. The intelligent high-bay warehouse according to claim 1, characterized in that: A pan-tilt platform is installed on the top of the four-way shuttle; a visual fault detection device is set on the pan-tilt platform; the visual fault detection device includes a visible light monitoring device and an infrared thermal imager.

6. The intelligent high-bay warehouse according to claim 4, characterized in that: The detection and control network equipment also includes a remote IO module and an on-site detection component; the on-site detection component 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 a redundant dual-power switch through a remote IO module, and then connected to multiple redundant controllers through the redundant dual-power switch.

7. The intelligent high-bay warehouse according to claim 6, characterized in that: The on-site detection component also includes a motor temperature sensor and a collision limit switch; the motor temperature sensor is located on the motors of the layer elevator, roller conveyor, and stacker, and each motor is equipped with a redundant motor temperature sensor; The collision limit switches are respectively arranged at the starting and end points of the roller conveyor, the limit points of the layer-changing elevator at the entrance and exit of each floor, the starting and end points of the four-way shuttle running track, and the starting and end points of the vertical and horizontal guide rails of the stacker; each limit point is provided with a redundant collision limit switch.

8. The intelligent high-bay warehouse according to claim 7, characterized in that: The detection and control network equipment also includes multiple wireless AP devices; each four-way shuttle control module and each stacker controller are connected to the wireless AP device; the wireless AP device is connected to a redundant dual-power switch.

9. The intelligent high-bay warehouse according to claim 8, characterized in that: The intelligent three-dimensional warehouse includes redundant host computers; each host computer has built-in dual Ethernet communication network cards and redundant hard drives; the host computer is connected to the on-site detection components, multiple redundant controllers, four-way shuttle control modules, stacker controllers, and inverter groups through redundant dual-power switches.

10. The intelligent high-bay warehouse according to claim 9, characterized in that: The high-bay warehouse also includes a frequency converter cabinet, a control cabinet, a network cabinet and an operation room; 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; and the host computer is located in the operation room.

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