ASRS Autonomous Orientation and Target Verification System

Abstract

The invention relates to a carry data-based routing and physical-digital mapping system that determines in real time the location, conveyor, line, or storage area to which pallets or materials stacked in intelligent warehouse (ASRS) systems should be directed.

Description

1 TARIFF ASRS Autonomous Orientation and Target Verification System Technical Area 5 The invention describes how pallets or materials are stacked in intelligent warehouse (ASRS) systems. location, which conveyor, which line or which storage area a carry data-based route that decides in real time which route to take It is related to identification and physical-digital mapping systems. 10 State of the Art In smart warehousing and intralogistics applications, determining the location of pallets or materials... The decision-making processes for directing decisions today mostly involve labeling, barcoding 15 Reading is done via manual identification or fixed rule sets. Therefore, the main shortcomings encountered in current systems are as follows: 1) Real-time matching between physical pallet and software data. not available. 20 Current solutions involve information carried on the pallet (product type, order information, target shelf). etc.) cannot be automatically transferred within the system. Because: • Scanning the barcode / label is mandatory to determine the pallet type. • Pallets are tracked separately in the digital system and in the physical workflow. 25 • Persistent synchronization errors between physical movement and software data. It consists of. 2) There is complete dependence on label machines and barcode scanner stations. In current warehouses: 30 • The label on each pallet must be read. • In case of reader malfunctions, the entire workflow stops. • If the label is erased / unreadable, the pallet cannot be recognized by the system. • The need for manual verification increases operational costs. 2 This dependency is a structural problem that limits warehouse efficiency. 3) There is no dynamic software intelligence to determine the target location of the pallet. In current practices: • Pallet routing is subject to fixed rules, 5 • Warehouse density, conveyor conditions, and real-time information from SAP are taken into consideration. not taken, • The system cannot decide "which pallet goes where" on its own. 4) Physical and digital flows do not proceed simultaneously. 10 In today's solutions: • The pallet moves physically, • The digital system updates information from a distance. • Incorrect shelving, incorrect output line, incorrect product due to data delay. Errors such as classification errors may occur. 15 Even the number of pallets processed in a single shift in warehouses is often reported manually. 5) Real-time inventory visibility and accurate counting are not possible. In label-based systems: • Real-time counting is not possible, 20 • Unreadable labels lead to stock errors. • The location of the pallet and the information about the product it contains cannot be verified simultaneously. 6) Current techniques do not have a "carry data" approach / data is accompanied by physical movement. It cannot be moved. 25 In current warehouse systems: • As the pallet moves, the data associated with it does not move. • Data is added to the system later through reading, transfer, or manual entry. • Therefore, pallet tracking is fragmented and prone to errors. In conclusion, under what conditions and in what ways is the routing and destination verification system important? Real-time assessments were made regarding the problems that would be encountered. The evaluations and comparisons of products manufactured using current technology have been carried out, due to the negative aspects described above and the solutions proposed regarding the issue 3 Due to its inadequacy, the ASRS Autonomous Guidance and Targeting that is the subject of our invention Innovation was required for the verification system. Brief Description of the Invention The present invention meets the aforementioned requirements and overcomes all the disadvantages. ASRS Autonomous Routing, which eliminates the need for such systems and brings some additional advantages. It is related to the Target Verification System. The primary purpose of the invention is to organize pallets or materials in smart warehouse systems. enabling the simultaneous transmission of data related to physical movement Our goal is to provide carry-data-based decision-making, navigation, and positioning software. Another aim of the invention is to completely eliminate dependence on labels and barcodes. • Data for each pallet is automatically transferred along with the physical movement, 15 • There is no obligation to print, read, or verify labels. • Eliminates operational risks such as labels being erased, falling off, or becoming unreadable. The goal is to remove it. Another aim of the invention is to have an autonomous decision-making mechanism. 20 Unlike existing ASRS systems, it only uses targets sent by SAP. It is not limited to applying shelf information. The system dynamically processes target information from SAP. It confirms this, but makes its own decision when there is a mismatch with the physical environment. You can redirect the pallet to an alternative location. • Even if the shelf space provided by SAP is full, it doesn't stop there; it determines a suitable empty shelf space itself. 25 • If the current target is not suitable according to the pallet size / product type, a new target is selected. • If the conveyor line is busy, it redirects to another route. • It re-routes without interrupting the operation flow. • Manual intervention by analyzing physical error / deviation situations. It provides a solution without requiring anything. Carry-data 30, implemented for the first time in warehouse automation. It is based on autonomous decision-making intelligence, unlike classical ASRS systems. It is not available. It speeds up the workflow within the warehouse and reduces downtime caused by errors. and increases the continuity of the operation. 4 Another aim of the invention is to make physical flow and software flow completely synchronized. The goal is to ensure it arrives. As the pallet moves along the conveyor: • The data it carries also moves within the system simultaneously, • There is no delay between the physical condition and the digital recording. • Errors such as incorrect shelving, incorrect order routing, and stock discrepancies 5 This feature significantly increases reliability in warehouse management. Another objective of the invention is to provide real-time inventory visibility and automated counting. • How many pallets are in the warehouse at that moment? • Which palette contains which products, 10 • Which line, shelf or point it is located on, • How many pallets are processed in one shift / hour It generates reports automatically. Eliminates the need for manual counting and potential errors. is the goal. Another objective of the invention is to create a system that works in full synchronization with conveyor and storage areas. The goal is to provide a routing engine. Thanks to the carry-data method, the system: • The conveyor on which the pallet is located, • Product characteristics on that conveyor, • The type of product the pallet carries, 20 • Existing warehouse capacity It analyzes the data instantly. This ensures the right pallet is placed in the right position in real time. is directed. Another objective of the invention is to integrate with SAP – PLC – MQTT – Node-RED systems. The goal is to ensure Industry 4.0 compliance through its work. The software is solely for in-warehouse routing. does not; at the same time: • Processes order and stock information received from SAP. • Transmits routing commands to the PLC. • Provides real-time visualization on the Node-RED interface, 30 • It enables high-speed data exchange via MQTT. This integrated structure enables full automation in warehouse processes. It aims to... Another aim of the invention is to increase warehouse efficiency and eliminate bottlenecks. to remove. • Downward movements caused by incorrect guidance are reduced. • Pallet flow is accelerated and balanced, • Unnecessary conveyor movements are prevented, 5 • Operation planning becomes easier. This represents a significant performance increase, especially in high-volume production facilities. The aim is to provide this. Another aim of the invention is to create a seamless bridge between physical life and software. The goal is to establish a system where physical transportation and digital data transportation are combined for the first time. They are merging. ASRS technologies represent a brand new approach in warehouse management. It dramatically improves both traceability and decision quality. The structural and characteristic features and all the advantages of the invention are given in Figure 15 below. And thanks to the detailed explanation written with references to these figures, it becomes clearer. This will be understood as such, and therefore the evaluation should also be based on these forms and details. This should be done taking the explanation into consideration. Figures to Help Understand the Invention 20 The subject of this application is "ASRS Autonomous Routing and Destination Verification". The "System" is shown in the attached figures; Figure 1: The subject of the invention is "ASRS Autonomous Guidance and Target Acquisition System". The schematic representation is a picture illustrating the matter. The drawings do not necessarily need to be scaled and are useful for understanding the invention. Unnecessary details may have been omitted. Furthermore, at least... 30 that are largely identical or at least have largely identical functions The elements are indicated by the same number. 6 Explanation of Part References 1. ASRS autonomous guidance and target verification system 2. Database 3. Server 4. Carry-Data Management Module 5 5. Dynamic Routing Motor 6. MQTT Communication Layer 7. Conveyor & Area Condition Monitoring Module 8. Node-RED Graphical Interface Module 9. IoT: Communication Between Things 10 10. Carry Data Management Software Detailed Description of the Invention This detailed explanation includes 15 points regarding the ASRS autonomous guidance and target verification system. preferred structures are solely for the purpose of better understanding the subject and It is explained in a way that will not create any limiting effects. The subject of the invention is the stacking of pallets or materials in intelligent warehouse (ASRS) systems. Real-time 20 for routing to location, conveyor, line or storage area. by making the decision, it completely eliminates the need for labeling or barcode scanning. lifting, decision-making in warehouse movements, routing, target setting, and Conveyor systems, robots, and guidance systems that handle traceability functions. compatible with covers, outlet lines, storage racks and other intralogistics equipment. 25 within the warehouse, which can be integrated into any factory using automation software. matching physical data flow with software data bidirectionally, dynamically and seamlessly, What product is the pallet carrying, where is it coming from, where is it going, and what processes is it going through? a carry data based system that allows passage to be determined without requiring label reading. ASRS autonomous routing and targeting provides route determination and physical-digital mapping. verification system(1) and its feature is; 30  pallets or materials stacked in smart warehouse (ASRS) systems Location, conveyor, routing information, pallet transport “carry data” information, Order, stock, or target shelf information from SAP, all within the warehouse Transportation and stacking operation information, pallets physically transported. 7 data (product information, pallet number, target location, work step) containing line or storage space information, transaction status information and including unit identification data, total conveyor route information, and structured to keep physical and digital data on record Database(2), 5  Data of the physically transported pallet (product information, pallet number, (target location, work step) simultaneously transferred in digital format providing, real-time guidance based on incoming data, and the location of the pallet equate the conveyor, rack line, or warehouse area with its counterpart in the software environment. synchronizing in time, during the physical movement of the pallet 10 The transported data is also recorded along with the physical location using the "carry data" method. It processes order, stock, or target shelf information received from SAP, all transportation within the warehouse that determines where the pallet goes, and It acts as a decision engine, providing real-time reports on stacking operations. Server(3) 15 It includes. This invention targets pallets or materials in an intelligent warehouse (ASRS) system. 20 multi-layered system that determines location and simultaneously manages physical and digital flow. It consists of a carry-data software architecture. Carry-Data Management Module(4) This module contains all data related to the physical movement of the pallet (product information, destination location, SAP reference, process step, etc.) enables simultaneous digital transfer. 25 Working principle: • As the pallet moves along the conveyor, the data it carries also moves. • Data from SAP matches physical movement. • Preventing the separation of physical and digital flows is essential for accurate routing. It produces the input. 30 This module is the core component of the invention that propagates transport data in an “untagged” manner. 8 Dynamic Routing Motor(5) This element verifies the target location sent by SAP and matches it with the physical environment. In case of incompatibility, it makes an autonomous decision and determines a new location. Working principle: • SAP target revenue → Matched with Carry-data. 5 • If the shelf is full, the pallet size is unsuitable, the conveyor is busy, or there is an error → The system sets a new target. • Physical data from Conveyor & Area Condition Monitoring Module (7) are analyzed It is done. • The most suitable alternative location is selected and a routing command is sent to the PLC. 10 This process occurs independently of the user. The Routing Motor is a patentable invention. It represents the ability to "make autonomous decisions". MQTT Communication Layer(6) This feature enables real-time data transmission between all modules. 15 Working principle: • Carry-data packets are continuously transmitted via MQTT. • New target information generated by the Dynamic Routing Engine (5) This information is transmitted to the PLC via this layer. • Seamless data flow is established between SAP and the interface. 20 • Real-time updated numerical values ​​from live message transmission of this layer It originates from. This element is the fundamental communication that enables the software to operate in real-time. It is its structure. Conveyor & Area Condition Monitoring Module(7) This element continuously monitors the condition of the physical equipment within the warehouse. Working principle: • Data such as conveyor speed / status information, equipment occupancy information, and rack capacity are available. 30 It is read. • This data is matched with carry-data for Dynamic Routing It is sent to the Motor(5). 9 • Whether the target location is physically suitable is determined by this module. It is determined. Status fields (e.g., field empty / full, orientation information, etc.) are the inputs for this module. When deciding on the Dynamic Routing Engine (5), consider the output of this module. He is required to use it. 5 Node-RED Visual Interface Module (8) The screen is the visual panel through which the operator has complete control over the software. Working principle: 10 • Carry-data is made visible here. • Target location selected by the Dynamic Routing Engine(5) The operator is notified. • Real-time conveyor status, process steps, and pallet information are presented to the user. • Operator intervention, if necessary, is done via the same screen. 15 This interface, while not a technical drawing, visually illustrates the functionality of the invention. It serves as a functional representation that explains [this]. General Flow of the Working Principle: 20 1. SAP sends the target shelf information. 2. Carry-Data Management Module (4) → matches the target information with the pallet data. 3. Conveyor & Area Condition Monitoring Module (7) → scans the physical environment. 4. Dynamic Routing Engine (5) → if the target is not suitable, its own 25 He makes his decision and identifies an alternative. 5. MQTT Communication Layer (6) → transmits the new target to the PLC. 6. Node-RED Visual Interface Module (8) → shows the entire situation in Figure 1. This workflow allows the system to manage both physical and digital movement within the warehouse simultaneously. and provides fully autonomous navigation. 30 This invention addresses the “decision-making and steering” layer of intelligent warehouse (ASRS) infrastructure. It operates as and is a central component of the overall system architecture. Software, connecting the physical transport flow within the warehouse with the corporate digital data flow. It is positioned as a carry-data based autonomous control layer. 5 System Components and Location of the Invention; The ASRS as a whole includes the following main components: • Physical conveying systems: conveyors, guide gates, shuttles, robotic carriers 10 • PLC-based control infrastructure: field signals, sensor data, device status knowledge • Enterprise ERP / SAP system: source of stock, order, and shelf target information. • Real-time communication infrastructure: MQTT protocols • Operator interface: Node-RED based monitoring panel 15 At the heart of this structure is the simultaneous processing of physical and digital data, and accurate targeting. The invention includes software that determines the location. The invention's position within the system is as follows: • SAP sets a target → the invention verifies the target 20 • Physical environment data is read → suitability for invention is checked • If the target is not suitable → the invention sets a new target. • The command is transmitted to the PLC → physical transport begins. • Displays interface status → carry-data is updated in real-time This structure, "decision-making + guidance + carry-data transfer," is entirely based on this invention 25. It shows that it is managed by. Interface: • Carry-data information, • The current position and status of the pallet, 30 • New targets generated by the Routing Engine, • Condition of physical equipment It visualizes in real time. 11 Therefore, the interface shows the system operator how the physical-digital data mapping of the invention is presented. It represents what it shows. The Role of the Invention within the Large Structure; This software is used in the ASRS architecture: • Decides which shelf / line the pallet will be directed to, 5 • Reconciles the physical environment with SAP data, • Synchronizes physical movement with digital carry-data information. • Ensures the operation flow continues uninterrupted. • Autonomous re-routing increases fault tolerance. Thus, the invention functions as the intelligence layer of the ASRS system, controlling the entire warehouse 10 It allows the movement to be managed in an accurate, reliable, and unlabeled manner. 20

Claims

12 REQUESTS 1. The invention relates to pallets or materials stacked in intelligent warehouse (ASRS) systems. Real-time 5 for routing to location, conveyor, line or storage area. by making the decision, it completely eliminates the need for labeling or barcode scanning. lifting, decision-making in warehouse movements, routing, target setting and conveyor systems, robots, which undertake traceability functions, directional covers, exit lines, storage racks and other intralogistics 10 compatible with equipment and integrated into every factory using automation software. It is possible to transmit software data bi-directionally, dynamically, and through the physical flow within the warehouse. seamlessly matching which product the pallet is carrying, where it's coming from and where it's going where it will go and what processes it will go through without needing to read the label. route planning based on carry data, enabling physical-digital integration. ASRS autonomous guidance and target verification system(1) 15 and its characteristic is;  pallets or materials stacked in smart warehouse (ASRS) systems Location, conveyor, routing information, pallet transport “carry data” information, Order, stock, or target shelf information from SAP, all within the warehouse Transportation and stacking operation information, pallets physically transported 20 data (product information, pallet number, target location, work step) containing line or storage space information, transaction status information and including unit identification data, total conveyor route information, and structured to keep physical and digital data on record Database(2), 25  Data of the physically transported pallet (product information, pallet number, (target location, work step) simultaneously transferred in digital format providing, real-time guidance based on incoming data, and the location of the pallet equate the conveyor, rack line, or warehouse area with its counterpart in the software environment. synchronizing in time, 30 during the physical movement of the pallet The transported data is also recorded along with the physical location using the "carry data" method. It processes order, stock, or target shelf information received from SAP, all transportation within the warehouse that determines where the pallet goes, and 13 It acts as a decision engine, providing real-time reports on stacking operations. Server(3) It includes.

2. ASRS Autonomous Orientation and Target Verification System conforming to Claim 1 5 Its feature is that it carries data (product, target, SAP information, process step, etc.) advancing the physical flow simultaneously, data to SAP, PLC and Node-RED It includes the Carry-Data Management Module (4) which carries between them.

3. ASRS Autonomous Orientation and Target Verification System conforming to Claim 1 of the invention. Its feature is that it verifies the SAP target information, and the target is physically available. Otherwise, it selects an alternative rack / line, makes autonomous decisions, and performs the re-routing operation. It includes a Dynamic Routing Engine (5).

4. ASRS Autonomous Orientation and Target Verification System conforming to Invention Claim 1. Its feature is that it enables real-time data exchange between PLC, SAP, and Node RED. MQTT Communication 15 provides and maintains carry-data packets in constant communication. It contains layer(6).

5. ASRS Autonomous Orientation and Target Verification System conforming to Invention Claim 1. and its characteristics include the pallet's physical conveyor line, warehouse space, equipment status and Conveyor & that reads capacity data and provides input to the steering motor. It includes the Field Condition Monitoring Module(7). 20 6. ASRS Autonomous Orientation and Destination Verification System conforming to Invention Claim 1. Its feature is that it allows the operator to monitor the entire flow and intervene when necessary. It includes the Node-RED Visual Interface Module (8), which enables it to do so. 30

Images