Stacker Control via Image Recognition for Warehouse Communication Failure
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Solution Overview
Problem
The existing technologies in chemical fiber production face challenges in improving the efficiency and safety of stackers in three-dimensional warehouses, particularly when communication between the stacker and the warehouse management system is interrupted.
Innovation Solution
A control method and apparatus for a stacker that utilizes an image recognition system to acquire warehouse state information, determine temporary work tasks, and send task instructions to the stacker, enabling it to execute tasks autonomously even when communication with the warehouse management system is interrupted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stacker relies on continuous communication with the warehouse management system to execute tasks, then task execution reliability is improved, but system complexity and vulnerability to communication interruptions increase
Solution Approach 1:
The image recognition system captures and processes warehouse state information in advance, storing it locally. When communication with the warehouse management system is interrupted, the stacker can immediately access pre-processed warehouse state information and continue executing tasks without waiting for system responses, thus maintaining task execution reliability while reducing dependency on continuous communication
Solution Approach 2:
An intermediate buffer zone is introduced between the warehouse management system and the stacker, consisting of locally stored warehouse state information and an image recognition system. This intermediary layer allows the stacker to operate autonomously using cached information when communication is interrupted, while still being able to synchronize with the central system when available, effectively decoupling the stacker's operational reliability from communication stability
2Productivity
If the stacker operates autonomously using image recognition during communication interruptions, then productivity is improved, but measurement precision and decision accuracy may deteriorate
Solution Approach 1:
The patent replaces the traditional mechanical/centralized control system with an image recognition-based autonomous decision system. The image recognition model processes visual information to identify warehouse states, replacing the need for continuous central system communication. This substitution enables the stacker to maintain high productivity during communication interruptions while achieving sufficient recognition accuracy through advanced image processing algorithms
Solution Approach 2:
The image recognition system creates a digital copy or representation of the warehouse state through image processing. Instead of relying on real-time data from the warehouse management system, the stacker uses captured images and their processed representations to understand warehouse conditions, enabling autonomous operation with adequate decision-making accuracy
3Adaptability or versatility
If real-time image recognition is performed to determine warehouse state, then adaptability to communication interruptions is improved, but energy consumption and processing time increase
Solution Approach 1:
Instead of continuous real-time image recognition, the system performs image capture and processing periodically or event-triggered. The image recognition system processes images at intervals or when specific conditions are met, rather than continuously analyzing every change. This periodic operation reduces energy consumption while maintaining the ability to adapt to communication interruptions by having updated warehouse state information available at regular intervals
Solution Approach 2:
The image recognition system performs preliminary processing of warehouse state information in advance and stores it locally. Rather than performing heavy image processing in real-time when needed, the system pre-processes images and caches the results, reducing the computational energy required during actual stacker operations and communication interruption events
Data Source
AI summary
Provided are a control method of a stacker and a three-dimensional warehouse automation system, relating to the field of chemical fiber intellectualization technology. The method includes: acquiring an intermediate table in response to receiving a task allocation request sent from the stacker; recognizing images in a first lane of a three-dimensional warehouse through an image recognition model to obtain warehouse state information of warehouse locations in the first lane; determining a temporary work task of the stacker based on the intermediate table; determining, based on the warehouse state information of the warehouse locations in the first lane, a position of a target warehouse location corresponding to the temporary work task; and sending the temporary work task and the position of the target warehouse location to the stacker, so that the stacker executes the temporary work task based on the position of the target warehouse location.