CN108996099B - Automatic stereoscopic warehouse scheduling system and control method thereof - Google Patents
Automatic stereoscopic warehouse scheduling system and control method thereof Download PDFInfo
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- CN108996099B CN108996099B CN201811154356.5A CN201811154356A CN108996099B CN 108996099 B CN108996099 B CN 108996099B CN 201811154356 A CN201811154356 A CN 201811154356A CN 108996099 B CN108996099 B CN 108996099B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
- B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses an automatic stereoscopic warehouse scheduling system and a control method thereof, wherein the system comprises a WMS/ERP system and an operation platform, wherein the operation platform is used for acquiring real-time logistics operation data, receiving and processing task instructions issued by the WMS/ERP system, and carrying out real-time control and real-time image display on logistics flows according to the task instructions; the operation platform comprises an operation management server, a database, a UI interface, a first-layer warehouse control subsystem and a second-layer warehouse control subsystem; the warehouse one-layer control subsystem comprises a warehouse mechanism controller group, a one-layer stacker controller group, an RGV controller, a lifting mechanism controller and a one-layer warehouse-out mechanism controller group; the warehouse two-layer control subsystem comprises an input-output mechanism controller group and a two-layer stacker controller group. The remarkable effects are as follows: optimizing the allocation scheme of the resources of different operation links and realizing reasonable allocation of personnel and equipment.
Description
Technical Field
The invention relates to the technical field of logistics warehouse scheduling management, in particular to an automatic stereoscopic warehouse scheduling system and a control method thereof.
Background
The working mode of the existing part distribution center mainly comprises team division cooperation, the whole process from arrival to arrival is split into sub-processes, each sub-process is arranged to be executed by a plurality of fixed working teams, for example, arrival processes, and after a truck arrives at a specified unloading port, the team specially responsible for the current unloading port executes the operations of unloading, checking, warehousing and the like. The personnel scheduling is driven by passive tasks, and the driving source of the tasks directly depends on the delivery bill of the provider, the homing bill and the picking bill issued by the WMS/ERP system.
The modern logistics is an automatic stereoscopic warehouse, is a trend of warehouse development, can effectively improve space utilization rate, reduces logistics cost, and has incomparable advantages for improving enterprise warehouse and production management level and the like. The automatic stereoscopic warehouse is a random complex system, particularly when the system is subjected to high-intensity and large-batch rapid picking operation, if the operation is only carried out in sequence, the conditions of conflict, shared resource competition and the like are ignored, and due to the random distribution of target cargo sites of the picking operation tasks, a large amount of idle invalid operation time exists when the stacker is carried out between the preceding operation tasks and the following operation tasks, so that the effective operation time and the path of the system cannot be optimized, and the overall operation efficiency of the system is greatly reduced.
In addition, in the prior art, each working link team is only responsible for tasks in the working area and does not basically participate in other link work, and in doing so, although the stability of independent operation of all processes can be ensured, the integrity of the logistics process is lacking, and the maximization of resource utilization cannot be realized. The phenomenon that a certain unloading opening is idle in a certain period of time, but the unloading opening on the other side is very busy, so that the allocation is uneven, a certain resource waste is caused, the production flexibility is low, and the logistics processing time is long. How to improve the utilization rate of equipment, reasonably allocate operators, reduce the inventory, and avoid the waste of funds, manpower and time to be the problem to be solved in the logistic operation management process of enterprises.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide an automatic stereoscopic warehouse scheduling system and a control method thereof, which can optimize the allocation scheme of different operation link resources and realize reasonable allocation of personnel and equipment.
In order to achieve the above purpose, the invention adopts the following technical scheme:
an automatic stereoscopic warehouse scheduling system is characterized in that: the system comprises a WMS/ERP system and an operation platform, wherein the operation platform is used for acquiring real-time logistics operation data, receiving and processing task instructions issued by the WMS/ERP system, and carrying out real-time control and real-time image display on logistics flows according to the task instructions;
the operation platform comprises an operation management server, a database, a UI interface, a first-layer warehouse control subsystem and a second-layer warehouse control subsystem;
the warehouse one-layer control subsystem comprises a warehouse mechanism controller group, a one-layer stacker controller group, an RGV controller, a lifting mechanism controller and a one-layer warehouse-out mechanism controller group;
the warehouse two-layer control subsystem comprises an input-output mechanism controller group and a two-layer stacker controller group.
Further, the control object of the warehouse-in controller group comprises an annular conveying line, one side of the annular conveying line is provided with a plurality of film winding warehouse-in conveying lines, a KD piece conveying line and an abnormal goods and inventory conveying line, the film winding warehouse-in conveying lines are used for automatically completing the code scanning, weighing, film winding and appearance detection of the goods, and the film winding warehouse-in conveying lines are used for completing the code scanning and weighing of the goods; the abnormal goods and inventory conveyor line is used for completing output of the abnormal goods, and warehousing of inventory after abnormal treatment without winding a film tray; the other side of the annular conveying line is provided with a plurality of groups of high-rise shelves, and a stacker is arranged between two adjacent groups of high-rise shelves.
Furthermore, the control object of the warehouse-in controller group further comprises an empty tray automatic replenishment cache line for storing empty trays, and the empty tray automatic replenishment cache line and the film winding warehouse-in conveying line or the film non-winding warehouse-in conveying line are arranged on the same side of the annular conveying line in parallel.
Further, the control object of the one-layer delivery mechanism controller group comprises a layer of goods cache line and a layer of delivery conveying line, a tray stacking machine is arranged on the one-layer delivery conveying line, an RGV conveying line is laid between the one-layer delivery conveying line and the automatic empty tray replenishment cache line, and the RGV conveying line is used for realizing the warehouse entry of the empty tray according to the instruction of the RGV controller.
Further, the control object of the warehouse in-out mechanism controller group comprises a two-layer goods cache line and a two-layer goods in-out conveying line, wherein the two-layer goods in-out conveying line is provided with two-layer tray stacking machines, the two-layer tray stacking machines are used for conveying empty trays after stacking to one layer of the warehouse through a lifting mechanism, and the lifting mechanism is used for conveying goods and the empty trays between one layer of the warehouse and two layers of the warehouse according to instructions of the lifting mechanism controller.
The invention also provides an automatic stereoscopic warehouse scheduling control method, which comprises the following steps:
step 1: the operation platform receives a task request instruction issued by a manual assignment or a WMS/ERP system;
step 2: the operation platform generates a task according to the task request instruction and issues the task to a warehouse control subsystem;
step 3: and the warehouse control subsystem performs at least one of a warehouse first-layer cargo warehousing process, a warehouse first-layer cargo ex-warehouse process, a warehouse second-layer cargo ex-warehouse process, an empty tray warehousing process or an empty tray ex-warehouse process according to task selection.
Further, the warehouse one-layer cargo warehousing process comprises the following specific steps:
step A1: finishing goods and labeling according to the tasks;
step A2: judging whether the goods need to be wound with the film, if so, sending the goods into the film winding and warehousing conveying line, otherwise, sending the goods into the film non-winding and warehousing conveying line;
step A3: after the goods on the film winding and warehousing conveying line or the film winding and warehousing conveying line are scanned and weighed respectively, judging whether the goods need to be wound with the film or not again;
for the goods on the film winding and warehousing conveying line, if film winding is needed, the warehouse control subsystem controls the film winding machine to work, then the goods after film winding and the goods without film winding are subjected to appearance inspection and are subjected to appearance inspection to finish warehousing by a stacker, and the goods with the appearance inspection problem returns to the step A1 through an abnormal goods outlet;
and (3) returning to the step A1 through an abnormal cargo outlet when the film winding is judged to be needed for the cargoes on the film winding-free warehousing conveying line, and finishing warehousing by a stacker when the film winding is not needed.
Further, the specific steps of the warehouse one-layer cargo delivery process are as follows:
step B1: the warehouse control subsystem controls the stacker to operate according to the issued task, and extracts pallet goods;
step B2: the warehouse control subsystem controls the stacker to convey pallet cargoes to a layer of cargo buffer line;
step B3: pallet cargos on the one-layer cargo buffer line are conveyed to a cargo outlet conveyor capable of being conveyed in two directions through a layer of cargo conveying line, and pallet cargos are forked to a ladle overturning area by a forklift to finish delivery;
step B4: and stacking the empty trays after forking the cargoes by a stacking tray machine, and realizing warehouse entry of the empty trays by an RGV conveying line.
Further, the specific steps of the empty tray warehouse-in process are as follows:
step C1: the forklift separates the pallet from the goods, and then returns the empty pallet to the shipment conveyor line;
step C2: the warehouse control subsystem controls the operation of the disc stacking machine to stack the empty trays;
step C3: judging the position of the empty tray, if the empty tray is positioned on the second layer of the warehouse, transferring the second layer of empty tray to the first floor through a lifter, and then carrying the empty tray to a warehouse-in position close to the stereoscopic warehouse through an RGV conveying line;
step C4: and the operation platform determines whether the empty trays are required to be replenished according to the number of the empty trays at the warehouse-in position of the stereoscopic warehouse, if so, the empty trays are sent to a required place through the annular conveying line, the empty trays are stored into an automatic replenishment cache line of the empty trays, and if so, the empty trays are sent to the stereoscopic warehouse.
Further, the specific steps of the empty tray ex-warehouse process are as follows:
step D1: the WMS system issues an empty tray replenishment instruction, and the warehouse control subsystem controls the stacker to operate according to the instruction to move the empty tray out of the high-level goods shelf and convey the empty tray to the annular conveying line;
step D2: the empty tray is moved to a goods supplementing demand place through the annular conveying line, and the empty tray is stored in the empty tray to automatically supplement the cache line;
step D3: the warehouse control subsystem controls the disc disassembling machine to disassemble the stacked empty trays;
step D4: and moving the single empty tray to a warehouse entry port of the stereoscopic warehouse through a transplanter.
The invention has the remarkable effects that: the resource allocation problem under the condition of fluctuation of the production plan is solved by optimizing and selecting allocation schemes of resources of different operation links and reasonably allocating personnel and equipment, so that the equipment utilization rate is improved, the allocation of the operation personnel is reasonable, the inventory is reduced, and the waste of funds, manpower and time is avoided under the condition that the equipment and the personnel are not newly added; and the material distribution requirement of the main machine factory under the condition that the line speed is increased by 10% is met, and the continuous and stable operation of the production operation is ensured, so that good economic benefit is obtained.
Drawings
FIG. 1 is a block diagram of the system components of the present invention;
FIG. 2 is a schematic layout of a layer of a warehouse according to the present invention;
FIG. 3 is a schematic layout of two layers of the warehouse of the present invention;
FIG. 4 is a flow chart of a warehouse entry process for a layer of goods in the warehouse;
FIG. 5 is a flow chart of a layer of shipment of the warehouse;
FIG. 6 is a flow chart of the warehouse two-tier cargo out process;
FIG. 7 is a flow chart of the empty pallet warehousing process;
fig. 8 is a flowchart of the empty tray ex-warehouse process.
Detailed Description
The following describes the embodiments and working principles of the present invention in further detail with reference to the drawings.
As shown in fig. 1, an automated stereoscopic warehouse scheduling system comprises a WMS/ERP system and an operation platform, wherein the operation platform is used for acquiring real-time logistics operation data, receiving and processing task instructions issued by the WMS/ERP system, and performing real-time control and real-time image display on a logistics flow according to the task instructions;
the operation platform comprises an operation management server, a database, a UI interface, a first-layer warehouse control subsystem and a second-layer warehouse control subsystem;
the warehouse one-layer control subsystem comprises a warehouse mechanism controller group, a one-layer stacker controller group, an RGV controller, a lifting mechanism controller and a one-layer warehouse-out mechanism controller group;
the warehouse two-layer control subsystem comprises an input-output mechanism controller group and a two-layer stacker controller group.
Referring to fig. 2, the stereoscopic warehouse is only warehouse-in from one layer, so that the control object of the warehouse-in controller group comprises an annular conveying line 1, three film winding warehouse-in conveying lines 2, two film winding warehouse-in conveying lines 3, one KD piece conveying line 4 and one abnormal goods and inventory conveying line 5 are arranged on one side of the annular conveying line 1, a code scanning machine 6, a weighing device 7, a film winding machine 8 and an appearance detecting machine 9 are arranged on the film winding warehouse-in conveying line 2, and the code scanning machine 6, the weighing device 7, the film winding machine 8 and the appearance detecting machine 9 are used for automatically finishing code scanning, weighing, film winding and appearance detection of the goods; the film winding-free warehousing conveying line 3 is also provided with a code scanning machine 6 and a weighing device 7 for finishing the code scanning and weighing of cargoes; the abnormal goods and inventory conveyor line 5 is used for completing output of the abnormal goods, and warehousing of inventory after abnormal treatment without winding a film tray; the other side of the annular conveying line 1 is provided with a plurality of groups of high-rise shelves 10, and a layer of stacker 11 is arranged between two adjacent groups of high-rise shelves 10.
The control object of the warehouse-in controller group further comprises an empty tray automatic replenishment cache line 12 for storing empty trays, and the empty tray automatic replenishment cache line 12 and the film winding warehouse-in conveying line 2 or the film non-winding warehouse-in conveying line 3 are arranged on the same side of the annular conveying line 1 in parallel. The specific setting mode is as follows: a film winding and warehousing conveying line 2, an empty tray automatic replenishment buffer line 12, a film winding and warehousing conveying line 3 and a film winding and warehousing conveying line 2 are sequentially arranged on the left side of a layer of warehousing opening of the warehouse from left to right, a film winding and warehousing conveying line 2, a film winding and warehousing conveying line 3, an empty tray automatic replenishment buffer line 12, a KD piece conveying line 4 and an abnormal goods and coil warehouse conveying line 5 are sequentially arranged on the right side of the layer of warehousing opening of the warehouse from left to right, and the empty tray automatic replenishment buffer line 12 and the central line of the KD piece conveying line 4 are positioned on the same straight line. Two layers of building structures can be arranged in the middle of the warehouse at one layer of warehouse-in end, one layer is a central control room, and the other layer is a steel platform visit area.
The control object of the one-layer delivery mechanism controller group comprises a layer of goods cache line 13 and a layer of delivery conveying line 14, a tray stacking machine 15 is arranged on the one-layer delivery conveying line, an RGV conveying line 16 is laid between the one-layer delivery conveying line 14 and the automatic empty tray replenishment cache line 12, and the RGV conveying line 16 is used for realizing the storage of the empty tray according to the instruction of the RGV controller.
Referring to fig. 3, the control objects of the warehouse entry and exit mechanism controller set include a two-layer cargo buffer line 17 and a two-layer cargo entry and exit conveyor line 18, which are located at two layers of the warehouse, the two-layer cargo buffer line 17 and the two-layer cargo entry and exit conveyor line 18 are located above the annular conveyor line 1 and at the front side of a two-layer high-level shelf 24 of two layers of the warehouse, and a two-layer stacker 23 is disposed between two adjacent two groups of two-layer high-level shelves 24; the two-layer goods entering and exiting conveying line 18 is provided with two stacking tray machines 19, the two stacking tray machines 19 convey the stacked empty trays to one layer of the warehouse through a lifting mechanism 20, and the lifting mechanism 20 is used for conveying goods and the empty trays between one layer of the warehouse and two layers of the warehouse according to instructions of a lifting mechanism controller.
In summary, the present scheduling system may be divided into four subsystems: the warehouse management subsystem, the data acquisition subsystem, the monitoring and dispatching subsystem and the control execution subsystem. The warehouse management subsystem mainly comprises functional modules of warehouse management, inventory management, ex-warehouse management, quality control, batch tracking, query statistics, system management and the like, and can be connected with an upper-level WMS/ERP system to form a subnet for realizing data sharing of inventory management with the WMS/ERP system.
The data acquisition subsystem is a first direct source of product information in the whole warehouse management process and generally comprises three parts, namely warehouse entry information acquisition (namely label code scanning), warehouse-out delivery confirmation and inventory checking. The method collects a large amount of data at high speed through an RF radio frequency identification technology and a bar code technology, reduces manual entry to the maximum extent, and ensures the accuracy of stock quantity.
The monitoring and dispatching subsystem is a core system for realizing automation and intellectualization of warehouse operations, and is responsible for managing and dispatching operation queues of the warehouse logistics information system, carrying out optimized combination queuing on the sequence of the operations according to the principles of shortest operation time, reasonable coordination among the operations and the like, analyzing the operation queues into instruction queues of automatic warehouse equipment, and commanding and coordinating the operation of the equipment according to the operation condition of the equipment; and meanwhile, the running condition of the automatic storage equipment is monitored by a dynamic simulation man-machine interaction interface.
The control execution subsystem takes each equipment PLC controller as a center, receives task information from an upper computer, collects information of each logistics equipment sensing system, and controls the output of the PLC controller through control software of the PLC controller so as to control the movement of each logistics equipment and realize the correct execution of logistics operation; and sends a layer of real-time state information of equipment such as the stacker 11 and the like to an operation management server in the operation platform so as to realize the real-time monitoring function of logistics equipment.
Based on the scheduling system, the embodiment also provides an automatic stereoscopic warehouse scheduling control method, which comprises the following specific steps:
step 1: the operation platform receives a task request instruction issued by a manual assignment or a WMS/ERP system;
step 2: the operation platform generates a task according to the task request instruction and issues the task to the warehouse control subsystem, namely the warehouse one-layer control subsystem and the warehouse two-layer control subsystem;
step 3: according to the task instruction, the first-layer control subsystem and the second-layer control subsystem of the warehouse reasonably select at least one of a first-layer cargo warehousing process, a first-layer cargo ex-warehouse process, a second-layer cargo ex-warehouse process, an empty tray warehousing process or an empty tray ex-warehouse process, wherein:
the warehouse one-layer cargo warehousing process comprises the following specific steps:
step A1: finishing goods and labeling according to the tasks;
step A2: the forklift driver judges whether the cargoes need to be wrapped with films, if yes, the cargoes are sent into the film wrapping and warehousing conveying line 2, otherwise, the cargoes are sent into the film non-wrapping and warehousing conveying line 3, and meanwhile, corresponding information is input through the UI interface;
step A3: after the goods on the film winding and warehousing conveying line 2 or the film winding and warehousing conveying line 3 are scanned and weighed respectively through a code scanning machine 6 and a weighing device 7, judging whether the goods need to be wound with films or not again;
for the cargoes on the film winding and warehousing conveying line 2, if film winding is needed, a layer of control subsystem of the warehouse controls the film winding machine 8 to work, then the cargoes after film winding and the cargoes without film winding are inspected by the appearance detector 9 to be free of problems, the corresponding layer of stacker 11 is controlled by a layer of stacker controller group to finish warehousing, and the cargoes with the problems in appearance detection return to the step A1 through abnormal cargoes and abnormal cargo outlets of the inventory conveying line 5;
and (3) returning to the step (A1) through the abnormal goods and the abnormal goods outlet of the inventory delivery line 5 when the film winding is judged to be needed, and controlling the layer-by-layer stacker 11 to finish the storage by the layer-by-layer stacker controller group when the film winding is not needed.
The specific steps of the warehouse one-layer goods delivery process of the warehouse are as follows:
step B1: the warehouse control one-layer subsystem controls one-layer stacker 11 to operate according to the issued task, and extracts pallet goods;
step B2: the warehouse control layer subsystem controls a layer stacker 11 to convey pallet cargoes to a layer cargo buffer line 13;
step B3: pallet cargos on the layer of cargo buffer lines 13 are conveyed to a cargo outlet conveyor 21 capable of being conveyed in two directions through a layer of cargo conveying lines 14, and pallet cargos are forked to a turning area by a forklift to finish delivery; the bi-directional delivery port conveyor automatically returns the pallet to the delivery line 14 after the pallet is picked up by the forklift and the pallet is returned to the delivery line 14.
Step B4: the empty trays after the goods are forked are stacked by a stacking tray machine 15, and the empty trays are put into storage by an RGV conveying line 16.
The process of delivering the second-layer goods from the warehouse is similar to the process of delivering the first-layer goods from the warehouse, firstly, a second-layer stacker controller in the warehouse control second-layer subsystem controls the second-layer stacker 23 to operate according to the issued task so as to extract pallet goods from a second-layer high-layer goods shelf 24; then controlling the stacker 23 to convey pallet cargoes to the two-layer cargo buffer line 17; pallet cargos on the two-layer cargo buffer line 17 are conveyed to a cargo outlet conveyor 21 capable of being conveyed in two directions through a two-layer cargo conveying line 18, and are forked to a bag turning area by a forklift to finish delivery; the empty pallets after being picked are palletized by a two-palletizer 19 and sent to a warehouse by a lifting mechanism 20 for one deck and then warehouse entry of the empty pallets is accomplished via the RGV conveyor line 16.
The method comprises the following specific steps of:
step C1: the forklift separates the pallet from the goods and then returns the empty pallet to the first-layer delivery line 14 of the first layer of the warehouse or the second-layer delivery line 18 of the second layer of the warehouse;
step C2: the warehouse one-layer control subsystem controls the operation of the one-layer tray stacking machine 15 or the warehouse two-layer control subsystem controls the operation of the two-layer tray stacking machine 19 to stack empty trays;
step C3: judging the position of the empty pallet, if the empty pallet is on the second floor of the warehouse, transferring the second floor of the empty pallet to the first floor through the lifting mechanism 20, and then carrying the empty pallet to a warehouse-in position close to the stereoscopic warehouse through the RGV conveying line 16;
step C4: the operation platform determines whether empty trays are required to be replenished according to the number of the empty trays at the warehouse-in position of the stereoscopic warehouse, if yes, the empty trays are sent to a required place through the annular conveying line 1 and stored in the automatic empty tray replenishment cache line 12, and if no, the empty trays are sent to the stereoscopic warehouse.
The method for discharging the empty trays comprises the following specific steps of:
step D1: the WMS system gives an empty tray replenishment instruction, and the warehouse control one-layer system controls the one-layer stacker 11 to operate according to the instruction to move the empty tray out of the high-layer goods shelf 10 and convey the empty tray onto the annular conveying line 1;
step D2: moving the empty trays to the place where the replenishment is required by the annular conveyor line 1, and storing the empty trays in an empty tray automatic replenishment cache line 12;
step D3: the warehouse one-layer control subsystem controls the tray dismounting machine 22 to work so as to split the empty trays after being stacked;
step D4: and moving the single empty tray to a warehouse entry port of the stereoscopic warehouse through a transplanter.
After the layout of the conveying line is optimized, the average utilization rate of the stackers is increased to 76.23%, so that each stacker can work in a balanced mode, and the phenomena of partial overload operation and partial leisure placement are avoided. The average utilization rate of the optimized device RGV with lower utilization rate and the shipment temporary storage area is over 60 percent. The loading and transporting rate is improved, the performance of the equipment is fully utilized, the warehouse-in and warehouse-out processing requirements of the automatic stereoscopic warehouse can be well met under the optimized system resource allocation, and enough adjustment space is reserved for the equipment, so that the requirement of future development of the automatic stereoscopic warehouse is met. The equipment in the warehouse system is continuously adjusted and optimized, so that the purposes of improving the resource utilization efficiency, reducing the waste of idle resources, enabling the system to run more smoothly and improving the overall benefit of the automatic stereoscopic warehouse are achieved.
Claims (1)
1. The automatic stereoscopic warehouse scheduling control method is characterized in that the automatic stereoscopic warehouse scheduling system comprises a WMS/ERP system and an operation platform, wherein the operation platform is used for acquiring real-time logistics operation data, receiving and processing task instructions issued by the WMS/ERP system, and carrying out real-time control and real-time image display on logistics flows according to the task instructions; the operation platform comprises an operation management server, a database, a UI interface, a first-layer warehouse control subsystem and a second-layer warehouse control subsystem; the warehouse one-layer control subsystem comprises a warehouse mechanism controller group, a one-layer stacker controller group, an RGV controller, a lifting mechanism controller and a one-layer warehouse-out mechanism controller group; the control object of the warehouse entry mechanism controller group comprises an annular conveying line, wherein one side of the annular conveying line is provided with a plurality of film winding warehouse entry conveying lines, a KD (product distribution) piece conveying line and an abnormal goods and warehouse entry conveying line, the film winding warehouse entry conveying lines are used for automatically completing code scanning, weighing, film winding and appearance detection of goods, and the film winding warehouse entry conveying lines are used for completing code scanning and weighing of the goods; the abnormal goods and inventory conveyor line is used for completing output of the abnormal goods, and warehousing of inventory after abnormal treatment without winding a film tray; a plurality of groups of high-rise shelves are arranged on the other side of the annular conveying line, and a layer of stacker is arranged between two adjacent groups of high-rise shelves; the control object of the warehouse entry mechanism controller group also comprises an empty tray automatic replenishment cache line for storing empty trays, and the empty tray automatic replenishment cache line and the film winding warehouse entry conveying line or the film non-winding warehouse entry conveying line are arranged on the same side of the annular conveying line in parallel; the control object of the one-layer delivery mechanism controller group comprises a layer of goods cache line and a layer of delivery conveying line, a tray stacking machine is arranged on the one-layer delivery conveying line, an RGV conveying line is paved between the one-layer delivery conveying line and the automatic empty tray replenishment cache line, and the RGV conveying line is used for realizing the warehousing of the empty tray according to the instruction of the RGV controller; the warehouse two-layer control subsystem comprises an input-output mechanism controller group and a two-layer stacker controller group; the control object of the warehouse-in and warehouse-out mechanism controller group comprises a two-layer goods cache line and a two-layer goods-in and warehouse-out conveying line which are positioned on two layers of a warehouse, wherein the two-layer goods cache line and the two-layer goods-in and warehouse-out conveying line are positioned above the annular conveying line and are positioned on the front side of a two-layer high-rise goods shelf of the two layers of the warehouse, a two-layer stacker is arranged between two adjacent two-layer high-rise goods shelves, two stacking tray machines are arranged on the two-layer goods-in and warehouse-out conveying line, the two stacking tray machines convey the stacked empty trays to one layer of the warehouse through a lifting mechanism, and the lifting mechanism is used for conveying the goods and the empty trays between the first layer of the warehouse and the second layer of the warehouse according to instructions of the lifting mechanism controller;
the method comprises the following steps:
step 1: the operation platform receives a task request instruction issued by a manual assignment or a WMS/ERP system;
step 2: the operation platform generates a task according to the task request instruction and issues the task to a warehouse control subsystem, wherein the warehouse control subsystem comprises a warehouse one-layer control subsystem and a warehouse two-layer control subsystem;
step 3: the warehouse control subsystem performs at least one of a warehouse first-layer cargo warehousing process, a warehouse first-layer cargo ex-warehouse process, a warehouse second-layer cargo ex-warehouse process, an empty tray warehousing process or an empty tray ex-warehouse process according to task selection;
the warehouse one-layer cargo warehousing process comprises the following specific steps:
step A1: finishing goods and labeling according to the tasks;
step A2: judging whether the goods need to be wound with the film, if so, sending the goods into the film winding and warehousing conveying line, otherwise, sending the goods into the film non-winding and warehousing conveying line;
step A3: after the goods on the film winding and warehousing conveying line or the film winding and warehousing conveying line are scanned and weighed respectively, judging whether the goods need to be wound with the film or not again;
for the goods on the film winding and warehousing conveying line, if film winding is needed, the warehouse control subsystem controls the film winding machine to work, then the goods after film winding and the goods without film winding are subjected to appearance inspection and have no problem, and then the goods with the problem of appearance inspection are subjected to warehousing by a layer of stacker, and the goods with the problem of appearance inspection are returned to the step A1 through an abnormal goods outlet;
returning to the step A1 through an abnormal cargo outlet when the film winding is judged to be needed for the cargoes on the film winding-free warehousing conveying line, and finishing warehousing by a layer of stacker when the film winding is not needed;
the specific steps of the warehouse one-layer goods delivery process of the warehouse are as follows:
step B1: the warehouse control subsystem controls a layer of stacker to operate according to the issued task, and extracts pallet goods;
step B2: the warehouse control subsystem controls a layer of stacker to convey pallet cargoes to a layer of cargo buffer line;
step B3: pallet cargos on the one-layer cargo buffer line are conveyed to a cargo outlet conveyor capable of being conveyed in two directions through a layer of cargo conveying line, and pallet cargos are forked to a ladle overturning area by a forklift to finish delivery;
step B4: the empty trays after goods are forked are stacked by a stacking tray machine, and the warehouse entry of the empty trays is realized by an RGV conveying line;
the method comprises the following specific steps of:
step C1: the forklift separates the pallet from the goods, and then returns the empty pallet to a first-layer delivery line of a first layer of the warehouse or a second-layer delivery line of a second layer of the warehouse;
step C2: the warehouse control subsystem controls a disc stacking machine or two disc stacking machines to work so as to stack empty trays;
step C3: judging the position of the empty tray, if the empty tray is positioned on the second layer of the warehouse, transferring the second layer of empty tray to the first floor through a lifting mechanism, and then carrying the empty tray to a warehouse-in position close to the stereoscopic warehouse through an RGV conveying line;
step C4: the operation platform determines whether empty trays are required to be replenished according to the number of the empty trays at the warehouse-in position of the stereoscopic warehouse, if so, the empty trays are sent to a required place through an annular conveying line, and the empty trays are stored into an automatic replenishment cache line, and if not, the empty trays are sent to the stereoscopic warehouse;
the method for discharging the empty trays comprises the following specific steps of:
step D1: the WMS system issues an empty tray replenishment instruction, and the warehouse control subsystem controls a layer of stacker to operate according to the instruction to move the empty tray out of the high-level goods shelf and convey the empty tray to the annular conveying line;
step D2: the empty tray is moved to a goods supplementing demand place through the annular conveying line, and the empty tray is stored in the empty tray to automatically supplement the cache line;
step D3: the warehouse control subsystem controls the disc disassembling machine to disassemble the stacked empty trays;
step D4: and moving the single empty tray to a warehouse entry port of the stereoscopic warehouse through a transplanter.
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