CN115187171A - Control method for automatic sorting and shunting of conveying line - Google Patents
Control method for automatic sorting and shunting of conveying line Download PDFInfo
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Abstract
The invention provides a control method for automatic planning, sorting and shunting of a conveying line, which comprises the following steps: s1: placing a batching order; s2: matching and planning the batching demand; combining the same contents of the batching orders to form a batching order set; s3: planning a container picking port; planning the floor where the container is delivered and a container picking port in a sorting detail record table; s4: the sorting detail planning dispatch list is issued to a storage control system WCS, the sorting detail planning dispatch list is received, and corresponding outbound tasks to be executed are generated according to container codes in the sorting detail planning dispatch list; s5: sorting port data closed loop; after the containers arrive at the sorting port, the WCS monitors container in-place signals and sends container codes to the warehousing management system, the warehousing system sorts detailed records according to the container codes before matching, matched results are displayed on a screen above the sorting port or the whole outlet, and workers carry out corresponding sorting according to the content of the screen; thus, sorting opening data closed loop is completed.
Description
Technical Field
The invention relates to the field of intelligent storage and discharge management, in particular to a control method for automatic sorting and shunting of a conveying line.
Background
The effective management of the automatic stereoscopic warehouse is managed by the cooperation of the intelligent warehouse management system of the control layer and the warehouse control system of the execution layer.
The efficiency of sorting and shunting of the warehouse out of the warehouse directly influences the efficiency of the production operation of the whole company and the turnover rate of the warehouse. Therefore, the planning of material warehouse-out and the control method of sorting and shunting become the key problems for improving the production efficiency of the whole logistics. At present, most of three-dimensional automatic warehouse material distribution in the market is carried out by warehouse managers according to material distribution requirements of workshops, inventory trays are searched in a warehouse management system through materials, warehouse outlets are designated, commands are sequentially issued to WCS (worst case load) single execution of a control layer, finally the inventory outlets are manually carried out, required materials are selected, the material distribution workload is undoubtedly increased through the operation, and the material distribution efficiency is greatly reduced. Goods leaving the warehouse are calculated through a series of sorting data and then are distributed to sorting outlets through conveying lines, so that automation and control of sorting and distribution are effective means for improving the operating benefits of the automatic warehouse. A closed-loop control method is built according to the warehouse management operation characteristics, approximate dynamic programming is used for solving, and the effectiveness of the control method is verified through practical application.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a control method for automatic sorting and shunting of a conveying line.
In order to achieve the purpose, the invention adopts the following technical scheme: a control method for automatic sorting and shunting of a conveying line comprises the following steps:
s1, issuing a batching order, wherein the batching order comprises a batching order number, a batching type, a material name, a material code, a material batch, a sales order number, a work order number and a required quantity Qty i Encoding the library area;
the batching order number is the order number of the batching order, and the order number is unique;
the ingredient type is the service attribute of the ingredient, and the service attribute comprises production material receiving, finished product delivery, stock allocation, work order feeding, miscellaneous item delivery and material borrowing;
quantity of demand Qty i The amount of material required for an order; i is the number of orders;
the system also comprises a material receiving point configuration table, wherein the material receiving point configuration table comprises a material distribution type, a material receiving point and a floor; the material receiving points are unique values, each batching type corresponds to one material receiving point, and each material receiving point corresponds to one warehouse-out floor;
the material code is the only identification of the material type; the material batches are different stock batches under the same material code; the sales order number is the order number of the sales order; the worksheet number is a production line production sheet number;
the storehouse area code refers to a storehouse area code for storing the material, and each storehouse area code represents an area for storing the material;
the material name, the material code, the material batch, the sales order number and the work order number come from an ERP system;
the ERP system is a system for converting three major flows of an enterprise: a management information system for performing comprehensive integrated management on logistics, fund flow and information flow;
s2: matching and planning the burdening demand;
combining the same contents of the batching orders to form a batching order set;
the same contents of the batching orders mean that the material names, the material codes, the material batches, the sales order numbers, the work order numbers and the library area codes are all the same;
the order set includes material name, material code, material batch, sales order number, work order number, quantity and
encoding the library area;
the warehouse management system also comprises a warehouse material data table in the warehouse management system, wherein the warehouse material data table comprises material names, material codes, material batches, sales order numbers, package codes, the quantity of materials corresponding to each package code, container codes, warehouse area codes, work order numbers, warehouse entry time, goods position codes and container codes;
the package code refers to the code of the packing box and the packing container, and the code of each package is unique;
the quantity of the materials corresponding to each package code is the quantity of the materials in the packaging container;
the container code is the only code of the carrier for storing the package, and the carrier for storing the package comprises a material frame, a tray and a material barrel;
the goods position coding table comprises goods position codes, goods position serial numbers, a goods position layer, goods position columns and shallow and deep goods position marks; the shallow and deep goods position mark comprises Q and S, wherein Q is a shallow goods position, and S is a deep goods position;
the goods position codes in the goods position code table correspond to the goods position codes in the inventory material data table one by one;
for the shelf with single depth, inventory materials are matched according to the first-in first-out principle, which specifically comprises the following steps:
sorting for the 1 st time; in a warehouse material data table of a warehouse management system, taking a material name, a material code, a material batch, a sales order number, a work order number and a library area code as indexes, searching and matching, matching materials with the same material name, material code, material batch, sales order number, work order number and library area code, and sequencing according to the warehousing time of the materials to obtain a warehouse material sequencing table;
in the stock material sorting table, according to the first-in first-out principle, the quantity and sum of the materials meeting the order in the stock materials are screened out
The stock material of (2);
for the double-deep shelf, the stock materials are matched according to the first-in first-out principle and the first shallow-in-later deep principle, which specifically comprises the following steps:
the double-deep-position goods shelves are two goods shelves on one side of the same roadway, the first goods shelf close to the roadway is a shallow goods shelf, the second goods shelf is a deep goods shelf, goods are required to be taken from the deep goods shelf, and when goods are blocked on the shallow goods shelf, the shallow goods shelf is required to be moved away;
sorting for the 1 st time; in a warehouse material data table of a warehouse management system, taking a material name, a material code, a material batch, a sales order number, a work order number and a library area code as a 1 st retrieval condition, performing retrieval matching, matching materials with the same material name, the same material code, the same material batch, the same sales order number, the same work order number and the same library area code, and sequencing according to the warehousing time of the materials to obtain a 1 st warehouse material sequencing data set;
sequencing according to the warehousing time of the materials to obtain a 1 st warehousing material sequencing data set, so that the materials can be prevented from being retained in a warehouse for a long time, and the materials are prevented from exceeding the quality guarantee period;
the 1 st inventory material sorting data set comprises material names, material codes, material batches, sales order numbers, work order numbers, warehouse area codes, container codes, package codes, the quantity of materials corresponding to each package code, warehousing time, goods position codes, goods position sorting numbers, goods position layers, goods position columns and shallow and deep goods position marks; the shallow and deep cargo space mark comprises two identifiers Q and S, wherein Q represents a shallow cargo space, and S represents a deep cargo space;
adding two columns of 'whether goods exist in corresponding deep and shallow goods positions' and 'whether goods exist in the same deep and shallow goods positions' in the 1 st stock material sorting data set,
if the shallow-deep goods position mark in the 1 st inventory material sorting data set is Q, the shallow-deep goods position mark represents that the goods position in the double-deep goods positions is a shallow goods position, and whether goods exist in the corresponding deep-shallow goods position means whether the deep goods position in the double-deep goods positions exists goods, namely whether goods exist in the deep goods on the wall of the shallow goods position;
if the shallow and deep goods position mark in the 1 st warehouse material sorting data set is S, the shallow and deep goods position mark represents that the goods position in the double deep goods positions is a deep goods position, and whether goods exist in the corresponding deep and shallow goods positions means whether the shallow goods position in the double deep goods positions exists goods, namely whether goods exist in the shallow goods on the wall of the deep goods position;
setting the code corresponding to the cargo position corresponding to the deep and shallow cargo positions as the new location code;
inquiring in the inventory material data table by taking the new location code new cargo space code as an inquiry condition; if the result is found, the new location code new cargo bit code is represented as the new cargo bit code, and the value of whether the corresponding deep and shallow cargo bit corresponding to the new location code is good is represented as 'good';
if the search result is empty, it indicates that the value of "whether the corresponding deep and shallow cargo bit corresponding to the new location code is" good "is" no cargo ";
if the data set appears in the 1 st inventory material sorting data set, and the value of 'whether the corresponding deep and shallow goods positions have goods' is 'good' and the value of 'whether the deep and shallow goods positions have the same goods' is 'same goods';
if the goods are not in the 1 st inventory material sorting data set, and the value of 'whether the corresponding deep and shallow goods positions have goods' is 'good' and the value of 'whether the deep and shallow goods positions have the same goods' is 'different goods';
sorting for the 2 nd time; searching and sorting shallow and deep goods position mark columns in the 1 st inventory material sorting table by taking 'Q' as a 2 nd sorting condition to obtain a 2 nd inventory material sorting data set;
the Q is used as a 2 nd sorting condition for searching and sorting, so that a goods position easy to take goods can be obtained preferentially, and the goods taking time is reduced;
the 2 nd warehouse material sorting data set comprises material names, material codes, material batches, sales order numbers, work order numbers, warehouse area codes, container codes, packaging codes, the number of materials corresponding to each packaging code, warehousing time, goods position codes, goods position sorting numbers, goods position layers, goods position columns, shallow and shallow goods position marks, whether goods exist in corresponding deep and shallow goods positions and whether the deep and shallow goods positions are the same;
3, sorting; sorting the sorting data set of the stock materials of the 2 nd time under the sorting condition that the 'good' is taken as the 3 rd time in the situation that whether the corresponding deep and shallow goods position has goods or not, and sorting the data set A of the stock materials of the 2 nd time;
sorting the sorting data set of the inventory materials for the 2 nd time by taking 'good' as a 3 rd sorting condition when the corresponding deep and shallow goods positions are good or not, and exposing the deep goods positions corresponding to the shallow goods after the goods are preferentially taken so as to be convenient for taking the goods by the next order;
4, sorting; sorting the sorting data set A of the storage materials in the 2 nd time and sorting the data set B of the storage materials in the 2 nd time by taking 'different goods' as a 4 th sorting condition according to whether the goods in the same deep and shallow goods positions are the same;
sorting the sorting data set A of the stock materials of the 2 nd time by taking 'different goods' as a 4 th sorting condition, and after goods are preferentially taken, exposing deep goods positions corresponding to shallow goods so as to be convenient for taking goods in a next order;
sorting for the 5 th time; in the shallow and deep goods position mark column in the 2 nd inventory material sorting data set B, taking 'S' as a 5 th sorting condition; obtaining a 3 rd inventory material sequencing data set;
the cargo of the deep cargo can be taken out preferentially by taking the S as the 5 th sorting condition;
sorting for the 6 th time; in the 3 rd inventory material sorting data set, sorting the 3 rd inventory material sorting data set under the condition that 'no goods' is used as the 6 th sorting condition in the condition that whether the corresponding deep and shallow goods positions have goods or not to obtain a 3 rd inventory material sorting data set A;
sorting the 3 rd inventory material sorting data set by taking 'no goods' as a 6 th sorting condition, so that the shallow goods space can be prevented from being moved, and the goods taking time is reduced;
sorting for the 7 th time; in the 3 rd inventory material sorting data set A, sorting the 3 rd inventory material sorting data set A under the condition that 'good' is taken as the 7 th sorting condition in the situation that whether the corresponding deep and shallow goods positions are good or not to obtain a 3 rd inventory material sorting data set B;
the 'good' is taken as the 7 th sorting condition in the process of judging whether the corresponding deep and shallow goods positions are good, so that the deep goods positions can be exposed conveniently, and the goods can be taken conveniently by placing an order;
8, sorting; in the 3 rd inventory material sorting data set B, sorting the 3 rd inventory material sorting data set B under the condition that whether the deep and shallow cargo spaces are the same and the 8 th sorting condition is the same cargo to obtain a 3 rd inventory material sorting data set C;
the 8 th sorting condition of whether the deep and shallow goods positions are the same or not and the 'same goods' is taken as the 8 th sorting condition, so that the goods with the same deep goods positions can be exposed conveniently, and the same order or the next order can be taken conveniently;
9 th sorting; in the 3 rd stored material sorting data set C, sorting the 3 rd stored material sorting data set C under the condition that whether the deep and shallow goods positions are the same or not and the 9 th sorting condition is 'different goods', so as to obtain a 3 rd stored material sorting data set D;
if the deep and shallow goods positions are the same, the 'different goods' is taken as the 9 th sorting condition, so that the goods with different deep goods positions can be conveniently exposed, and the goods can be conveniently taken by the next order;
sorting for the 10 th time; in the 3 rd sorting data set D of the stock materials, sorting the 3 rd sorting data set D of the stock materials by taking the container code as a 10 th sorting condition to obtain a 3 rd sorting data set E of the stock materials;
the 3 rd stock material sorting data set D is sorted by taking the container code as the 10 th sorting condition, so that goods can be conveniently taken in one container, the goods are prevented from being taken in a plurality of containers by one order, and the goods taking speed is improved;
the 3 rd inventory material sorting data set E comprises material names, material codes, material batches, sales order numbers, work order numbers, warehouse area codes, container codes, package codes, the number of materials corresponding to each package code, warehousing time, goods position codes, goods position sorting numbers, goods position layers, goods position columns, shallow and deep goods position marks, whether goods exist in corresponding deep and shallow goods positions and whether the deep and shallow goods positions are the same;
on the basis of the 3 rd stock material sorting data set E, screening out the quantity of the materials meeting the order in the stock materials according to the sequence
Obtaining a stock material configuration list set;
matching the batching orders in the stock material configuration list to form a sorting detail record table;
adding a 'quantity of goods taken' column in a sorting detail record table;
specifically, a first record in the inventory material configuration list is matched with a first order; if the quantity of the materials corresponding to each packaging code is equal to the quantity of the materials required by the first order, successfully matching the first record in the inventory material configuration order with the first order, and filling the quantity of the materials required by the first order into the corresponding 'pick-up quantity';
if the quantity of the materials corresponding to each packaging code is larger than that of the materials required by the first order, successfully matching the first record in the inventory material configuration order with the first order; matching the first record in the stock material configuration list with the second order, and if the quantity of the materials corresponding to each packaging code minus the quantity of the materials required by the first order is equal to the quantity of the materials required by the second order, successfully matching the first record in the stock material configuration list with the second order; adding the quantity of the materials required by the second order to the corresponding 'quantity of the taken goods';
if the quantity of the materials corresponding to each packaging code minus the quantity of the materials required by the first order is larger than the quantity of the materials required by the second order, continuing to match the third order, and adding the quantity of the materials required by the third order to the corresponding 'quantity of the taken goods';
if the quantity is not enough, polling a second record, and repeating the steps and the polling until each record in the inventory material configuration list is successfully matched with the order, and finally planning to form a sorting detail record table;
the sorting detail record table comprises a batching list number, a batching type, a material name, a goods taking quantity, material codes, a material batch, a sales list number, a work list number, a library area code, a container code, a packaging code, the quantity of materials corresponding to each packaging code, warehousing time, a goods position code, a goods position serial number, a goods position layer, a goods position column, a shallow goods position mark, whether goods exist in a corresponding deep and shallow goods position and whether the deep and shallow goods positions are the same;
s3: planning a container picking port or a container finishing port; planning the floor for delivering the containers and the container sorting port or the whole outlet in the sorting detail record table;
3 columns of warehouse-out floors, whole outlets and sorting outlets are added in the sorting detail record table;
according to the ingredient types in the sorting detail record table obtained in the step S2, the ex-warehouse floors corresponding to the orders are inquired in the material receiving point configuration table, and the ex-warehouse floors are recorded in the ex-warehouse floors corresponding to the sorting detail record table;
each floor is provided with N conveying line channels, and the terminal of each conveying line channel is provided with a sorting opening or a whole outlet;
the whole outlet is an outlet which needs to take all the goods in the container out;
the picking port is a port which needs to take out part of the goods in the container and return the rest goods to the warehouse;
if the quantity of the goods is = the quantity in the container, filling the whole outlet in the corresponding row and the column corresponding to the whole outlet in the sorting detail record table;
through the planning of the whole outlet, the conveying efficiency and the goods picking efficiency are improved, and meanwhile, the emptying of containers and goods spaces is facilitated;
if the quantity of the picked goods is less than the quantity in the container, filling the corresponding sorting ports in the corresponding rows and columns corresponding to the sorting ports in the sorting detail record table according to the principle of uniform order;
finally, forming a sorting detail planning dispatch list;
the dispatching order is planned according to the optimal sorting detail, so that the utilization rate of storage and the efficiency of conveying logistics are improved, the intelligent working efficiency is improved, the labor workload is reduced, and a data basis is laid for the WCS of the storage control system to execute material issuing in the next step;
s4: issuing the sorting detail planning distribution order to a Warehousing Control System (WCS), receiving the sorting detail planning distribution order by the WCS, and planning the distribution order according to the sorting detail
Generating one-to-one corresponding ex-warehouse tasks to be executed;
after a container ex-warehouse command corresponding to the ex-warehouse task is issued to the warehousing control system, the warehousing control system WCS dynamically shunts the containers of the task according to the state of a PLC (programmable logic controller) on a line segment on the existing ex-warehouse route;
the annular line body consists of M sections of conveying lines, and each section of conveying line comprises a PLC state;
s41, the ex-warehouse task firstly carries the container to an ex-warehouse berthing platform corresponding to the current roadway through stacker equipment; a ring-shaped line body is arranged below the carrying platform, and the ring-shaped line body is an annular conveying line;
the berthing carrying platform is a first conveying line for taking down and placing the containers from the goods shelf by the stacker;
s42, before transferring the container flow to the annular line body at the position of the carrying platform, reading the number of the containers currently carried on the annular line body and the maximum carrying capacity of the annular line body, comparing, and finally transferring the container flow to the annular line body;
further, the step of comparing comprises the sub-steps of:
s421, if the number of containers currently carried on the ring-shaped wire body does not reach the maximum carrying capacity of the ring-shaped wire body, transferring the containers to the ring-shaped wire body;
s422, if the number of the containers currently carried on the ring-shaped line reaches the maximum carrying capacity of the ring-shaped line, the containers wait at the carrying platform until the reduction of the number of the containers carried by the line is monitored, and then the containers are continuously dispatched;
s423, continuously monitoring the warehousing task on the conveying line in the dispatching process, and if the warehousing task exists on the conveying line, executing the warehousing task by the conveying line;
by comparing the number of the containers currently carried with the maximum carrying capacity of the annular line body, the annular line body is prevented from being jammed, so that equipment stops running, cannot run or runs out of control;
by continuously monitoring the warehousing tasks on the conveying line, the conflict between the warehousing tasks and the ex-warehouse tasks when the conveying line jointly passes through a section of conveying line is prevented, so that the blockage is caused;
s43, before the container is transported to a sorting port or a whole outlet on the annular line body, reading the PLC state of a conveying line of the sorting port or the whole outlet, and if the PLC state of the conveying line shows occupied, continuing to circulate the container on the annular line body; if the PLC state of the conveying line shows that the conveying line is idle, the containers flow to a target sorting port or a whole outlet;
the PLC state of the conveying line at the sorting port or the whole outlet is read, so that the collision of the warehousing task and the ex-warehouse task on the conveying line at the sorting port or the whole outlet is prevented, and the blockage is caused;
s5: a sorting port or a whole outlet data closed loop;
after the containers arrive at the sorting port or the whole outlet, the warehousing control system WCS monitors container in-place signals and sends container codes to the warehousing management system, the warehousing system sorts detailed records according to the container codes before matching, matched results are displayed on a screen above the sorting port or the whole outlet, and workers carry out corresponding sorting according to the content of the screen; thus, a closed loop of sorting or finishing gate data is completed.
Further, when the containers arrive at the sorting port or the whole outlet, the storage control system WCS writes the container codes into PLC offsets corresponding to the sorting port or the whole outlet;
write in the container sign indicating number through storage control system WCS and sort the mouth or the whole PLC offset that the export corresponds, sort and accomplish no longer need read a sign indicating number equipment scanning container sign indicating number, press the storehouse of returning button and can return the storehouse with the container, reduced the input of equipment, facilitated the operation, promoted efficiency.
Compared with the prior art, the invention has the beneficial effects that: according to the control method for automatically planning sorting and shunting, the sorting detail record table is formed by automatically calculating and planning according to the batching demand,
Planning a container sorting port or a container sorting port to form an optimal sorting detail planning dispatch list; the dispatching order is planned according to the optimal sorting detail, so that the utilization rate of storage and the efficiency of conveying logistics are improved, the intelligent working efficiency is improved, and the labor workload is reduced; meanwhile, after a container ex-warehouse command corresponding to the ex-warehouse task is issued to the warehousing control system, the warehousing control system WCS dynamically shunts the containers of the task according to the state of the PLC on the line segment on the existing ex-warehouse route, so that the phenomenon that the equipment stops running, cannot run or run out of control due to the congestion of the annular line body is avoided, and the phenomenon that the equipment stops running, cannot run or runs out of control due to the conflict of the warehousing task and the ex-warehouse task on the conveying line is avoided, so that the blockage is caused. In addition, personnel at a sorting port can return to the warehouse only by scanning the code container, the operation is simple and easy, the personnel allocation of warehouse management is reduced, and the automatic telephone equipment is utilized to manage the warehouse to the maximum extent.
Drawings
FIG. 1 is a schematic flow chart of the present invention.
Detailed Description
In order to further understand the objects, structures, features and functions of the present invention, the following embodiments are described in detail.
Referring to fig. 1, the present invention provides a control method for automatic sorting and shunting of a conveyor line. S1, issuing a batching order, wherein the batching order comprises a batching order number, a batching type, a material name, a material code, a material batch, a sales order number, a work order number and a required quantity Qty i Encoding the library area;
the batching list number is the list number of the batching order and is unique;
the batching type is the service attribute of batching, and the service attribute comprises production material receiving, finished product delivery, stock allocation, work order feeding, miscellaneous item delivery and material borrowing;
quantity of demand Qty i The amount of material required for an order; i is the number of orders;
the system also comprises a material receiving point configuration table, wherein the material receiving point configuration table comprises a material distribution type, a material receiving point and a floor; the material receiving points are unique values, each batching type corresponds to one material receiving point, and each material receiving point corresponds to one warehouse-out floor;
the material code is the only identification of the material type; the material batches are different stock batches under the same material code; the sales order number is the order number of the sales order; the worksheet number is the production worksheet number of the production line;
the library area codes refer to library area codes for storing the materials, and each library area code represents an area for storing the materials;
the material name, the material code, the material batch, the sales order number and the work order number come from an ERP system;
the ERP system is a flow of three major enterprises: a management information system for comprehensively and integrally managing logistics, fund flow and information flow;
s2: matching and planning the batching demand;
combining the same contents of the batching orders to form a batching order set;
the material mixing order contents are the same, namely the material name, the material code, the material batch, the sales order number, the work order number and the storage area code are the same;
the order set includes material name, material code, material batch, sales order number, work order number, quantity and
encoding the library area;
the warehouse management system also comprises a warehouse material data table in the warehouse management system, wherein the warehouse material data table comprises material names, material codes, material batches, sales order numbers, package codes, the quantity of materials corresponding to each package code, container codes, warehouse area codes, work order numbers, warehouse entry time, goods position codes and container codes;
the package code refers to the code of the packaging box and the packaging container, and the code of each package is unique;
the quantity of the materials corresponding to each packaging code refers to the quantity of the materials in the packaging container;
the container code is the only code of the carrier for storing the package, and the carrier for storing the package comprises a material frame, a tray and a material barrel;
the goods position coding table comprises goods position codes, goods position serial numbers, a goods position layer, goods position columns and shallow and deep goods position marks; the shallow and deep goods position mark comprises Q and S, wherein Q is a shallow goods position, and S is a deep goods position;
the goods position codes in the goods position code table correspond to the goods position codes in the inventory material data table one by one;
for the shelf with single depth, the stock materials are matched according to the first-in first-out principle, and the method specifically comprises the following steps:
sorting for the 1 st time; in a warehouse material data table of a warehouse management system, taking a material name, a material code, a material batch, a sales order number, a work order number and a library area code as indexes, searching and matching, matching materials with the same material name, material code, material batch, sales order number, work order number and library area code, and sequencing according to the warehousing time of the materials to obtain a warehouse material sequencing table;
in the stock material sorting table, according to the first-in first-out principle, the quantity and sum of the materials meeting the order in the stock materials are screened out
The stock material of (1);
for the double-deep shelf, the stock materials are matched according to the first-in first-out principle and the first shallow-in-later deep principle, which specifically comprises the following steps:
the double-deep goods shelf is two goods shelves on one side of the same roadway, the first goods shelf close to the roadway is a shallow goods shelf, the second goods shelf is a deep goods shelf, goods are taken from the deep goods shelf, and when goods blocking exists on the shallow goods shelf, the shallow goods shelf needs to be removed;
sorting for the 1 st time; in a warehouse material data table of a warehouse management system, taking a material name, a material code, a material batch, a sales order number, a work order number and a library area code as a 1 st retrieval condition, performing retrieval matching, matching materials with the same material name, the same material code, the same material batch, the same sales order number, the same work order number and the same library area code, and sequencing according to the warehousing time of the materials to obtain a 1 st warehouse material sequencing data set;
sequencing according to the warehousing time of the materials to obtain a 1 st warehousing material sequencing data set, so that the materials can be prevented from being retained in a warehouse for a long time, and the materials are prevented from exceeding the quality guarantee period;
the 1 st storage material sorting data set comprises material names, material codes, material batches, sales order numbers, work order numbers, storage area codes, container codes, packaging codes, the quantity of materials corresponding to each packaging code, storage time, goods position codes, goods position sorting numbers, goods position layers, goods position columns and shallow and deep goods position marks; the shallow and deep goods position mark comprises two identifiers Q and S, wherein Q represents a shallow goods position, and S represents a deep goods position;
adding two columns of 'whether goods exist in corresponding deep and shallow goods positions' and 'whether goods exist in the same deep and shallow goods positions' in the 1 st stock material sorting data set,
if the shallow-deep goods position mark in the 1 st inventory material sorting data set is Q, the shallow-deep goods position mark represents that the goods position in the double-deep goods positions is a shallow goods position, and whether goods exist in the corresponding deep-shallow goods position means whether the deep goods position in the double-deep goods positions exists goods, namely whether goods exist in the deep goods on the wall of the shallow goods position;
if the shallow and deep goods position mark in the 1 st warehouse material sorting data set is S, the shallow and deep goods position mark represents that the goods position in the double deep goods positions is a deep goods position, and whether goods exist in the corresponding deep and shallow goods positions means whether the shallow goods position in the double deep goods positions exists goods, namely whether goods exist in the shallow goods on the wall of the deep goods position;
setting the code corresponding to the cargo position corresponding to the deep and shallow cargo positions as the new location code;
inquiring in the inventory material data table by taking the new location code new cargo space code as an inquiry condition; if the result is found, the new location code new cargo bit code is represented as the new location code corresponding to the corresponding deep and shallow cargo bit with cargo or not, and the value is 'cargo' or not;
if the search result is null, it indicates whether the corresponding deep and shallow cargo position corresponding to the new location code new cargo position code has cargo or not, and the value is "no cargo";
if the data set appears in the 1 st inventory material sorting data set, and the value of 'whether the corresponding deep and shallow goods positions have goods' is 'good' and the value of 'whether the deep and shallow goods positions have the same goods' is 'same goods';
if the goods are not in the 1 st inventory material sorting data set, and the value of 'whether the corresponding deep and shallow goods positions have goods' is 'good' and the value of 'whether the deep and shallow goods positions have the same goods' is 'different goods';
sorting for the 2 nd time; searching and sorting shallow and deep goods position mark columns in the 1 st inventory material sorting table by taking 'Q' as a 2 nd sorting condition to obtain a 2 nd inventory material sorting data set;
the Q is used as a 2 nd sorting condition for searching and sorting, so that a goods position easy to take goods can be obtained preferentially, and the goods taking time is reduced;
the 2 nd warehouse material sorting data set comprises material names, material codes, material batches, sales order numbers, work order numbers, warehouse area codes, container codes, packaging codes, the number of materials corresponding to each packaging code, warehousing time, goods position codes, goods position sorting numbers, goods position layers, goods position columns, shallow and shallow goods position marks, whether goods exist in corresponding deep and shallow goods positions and whether the deep and shallow goods positions are the same;
sorting for the 3 rd time; sorting the sorting data set of the stock materials in the 2 nd time by taking 'good' as a 3 rd sorting condition in the condition of whether the corresponding deep and shallow goods positions have goods, wherein the sorting data set A of the stock materials in the 2 nd time is a sorting data set A;
sorting the sorting data set of the stock materials of the 2 nd time under the sorting condition that the corresponding deep and shallow goods positions have goods or not and the goods are sorted under the sorting condition that the goods are available, wherein the deep goods positions corresponding to the shallow goods can be exposed after the goods are preferentially taken, so that the goods can be conveniently taken by a next order;
4, sorting; sorting the sorting data set A of the stock materials in the 2 nd time under the 4 th sorting condition that whether the deep and shallow cargo positions are the same or not and sorting the data set B of the stock materials in the 2 nd time;
sorting the sorting data set A of the stock materials of the 2 nd time under the sorting condition of 'different goods' as the 4 th time, and exposing the deep goods position corresponding to the shallow goods after the goods are preferentially taken, so that the goods can be conveniently taken by the next order;
sorting for the 5 th time; in the shallow and deep goods position mark column in the 2 nd inventory material sorting data set B, taking 'S' as a 5 th sorting condition; obtaining a 3 rd inventory material sequencing data set;
the cargo of the deep cargo can be taken out preferentially by taking the S as the 5 th sorting condition;
sorting for the 6 th time; in the 3 rd inventory material sorting data set, sorting the 3 rd inventory material sorting data set under the 6 th sorting condition of 'no goods' in the situation that whether the corresponding deep and shallow goods positions have goods or not to obtain a 3 rd inventory material sorting data set A;
sorting the 3 rd inventory material sorting data set by taking 'no goods' as a 6 th sorting condition, so that the shallow goods space can be prevented from being moved, and the goods taking time is reduced;
sorting for the 7 th time; in the 3 rd inventory material sorting data set A, sorting the 3 rd inventory material sorting data set A under the condition that 'good' is taken as the 7 th sorting condition in the condition that whether the corresponding deep and shallow goods positions are good or not to obtain a 3 rd inventory material sorting data set B;
the 7 th sorting condition of 'good' is taken as the condition whether the corresponding deep and shallow goods positions have goods or not, so that the deep goods positions can be conveniently exposed, and the goods can be conveniently taken by placing an order;
8, sorting; in the 3 rd inventory material sorting data set B, sorting the 3 rd inventory material sorting data set B under the condition that whether the deep and shallow cargo spaces are the same and the 8 th sorting condition is the same cargo to obtain a 3 rd inventory material sorting data set C;
whether the deep and shallow goods positions are the same or not and the 8 th sorting condition of the same goods is adopted, so that the goods with the same deep goods position can be conveniently exposed, and the same order or the next order can be conveniently taken;
sorting for the 9 th time; in the 3 rd stored material sorting data set C, sorting the 3 rd stored material sorting data set C under the condition that whether the deep and shallow goods positions are the same or not and the 9 th sorting condition is 'different goods', so as to obtain a 3 rd stored material sorting data set D;
if the deep and shallow goods positions are the same, the 'different goods' is taken as the 9 th sorting condition, so that the goods with different deep goods positions can be conveniently exposed, and the goods can be conveniently taken by the next order;
sorting for the 10 th time; in the 3 rd sorting data set D of the stock materials, sorting the 3 rd sorting data set D of the stock materials by taking the container code as a 10 th sorting condition to obtain a 3 rd sorting data set E of the stock materials;
the 3 rd inventory material sorting data set D is sorted by taking the container code as the 10 th sorting condition, so that goods can be conveniently taken in one container, the goods are prevented from being taken in a plurality of containers by one order, and the goods taking speed is increased;
the 3 rd stock material sorting data set E comprises material names, material codes, material batches, sales order numbers, work order numbers, warehouse area codes, container codes, package codes, the quantity of materials corresponding to each package code, warehousing time, goods position codes, goods position numbers, goods position layers, goods position columns, shallow and deep goods position marks, whether goods exist in corresponding deep and shallow goods positions and whether the deep and shallow goods positions are the same;
on the basis of the 3 rd stock material sorting data set E, screening out the quantity of the materials meeting the order in the stock materials according to the sequence
Obtaining a stock material configuration list set;
matching the batching orders in the stock material configuration list to form a sorting detail record table;
adding a 'quantity of goods taken' column in a sorting detail record table;
specifically, a first record in the inventory material configuration list is matched with a first order; if the quantity of the materials corresponding to each packaging code is equal to the quantity of the materials required by the first order, successfully matching the first record in the inventory material configuration order with the first order, and filling the quantity of the materials required by the first order into the corresponding 'pick-up quantity';
if the quantity of the materials corresponding to each packaging code is larger than that of the materials required by the first order, successfully matching the first record in the inventory material configuration order with the first order; matching the first record in the stock material configuration list with the second order, and if the quantity of the materials corresponding to each packaging code minus the quantity of the materials required by the first order is equal to the quantity of the materials required by the second order, successfully matching the first record in the stock material configuration list with the second order; adding the quantity of the materials required by the second order to the corresponding 'quantity of the taken goods';
if the quantity of the materials corresponding to each packaging code minus the quantity of the materials required by the first order is larger than the quantity of the materials required by the second order, continuing to match the third order, and adding the quantity of the materials required by the third order to the corresponding 'quantity of the taken goods';
if the quantity is not enough, polling a second record, and repeating the steps and the polling until each record in the inventory material configuration list is successfully matched with the order, and finally planning to form a sorting detail record table;
the sorting detail record table comprises a batching list number, a batching type, a material name, a goods taking quantity, material codes, a material batch, a sales list number, a work list number, a library area code, a container code, a packaging code, the quantity of materials corresponding to each packaging code, warehousing time, a goods position code, a goods position serial number, a goods position layer, a goods position column, a shallow goods position mark, whether goods exist in a corresponding deep and shallow goods position and whether the deep and shallow goods positions are the same;
s3: planning a container picking port or a container finishing port; planning the floor for delivering the containers and the container sorting port or the whole outlet in the sorting detail record table;
3 columns of warehouse-out floors, whole outlets and sorting outlets are added in the sorting detail record table;
according to the ingredient types in the sorting detail record table obtained in the step S2, the ex-warehouse floors corresponding to the orders are inquired in the material receiving point configuration table, and the ex-warehouse floors are recorded in the ex-warehouse floors corresponding to the sorting detail record table;
each floor is provided with N conveying line channels, and the terminal of each conveying line channel is provided with a sorting port or a whole outlet;
the whole outlet is an outlet which needs to take all the goods in the container out;
the picking port is a port which needs to take out part of the goods in the container and return the rest goods to the warehouse;
if the quantity of the goods is = the quantity in the container, filling the whole outlet in the corresponding row and the column corresponding to the whole outlet in the sorting detail record table;
through the planning of the whole outlet, the conveying efficiency and the goods picking efficiency are improved, and meanwhile, the emptying of containers and goods spaces is facilitated;
if the quantity of the picked goods is less than the quantity in the container, filling the corresponding sorting ports in the corresponding rows and columns corresponding to the sorting ports in the sorting detail record table according to the principle of uniform order;
finally, forming a sorting detail planning dispatch list;
the dispatching order is planned through optimal sorting detail, so that the storage utilization rate and the logistics conveying efficiency are improved, the intelligent working efficiency is improved, the labor workload is reduced, and a data basis is laid for the next step of material issuing execution of a WCS (warehouse control system) by the storage control system;
s4: issuing the sorting detail planning distribution order to a Warehousing Control System (WCS), receiving the sorting detail planning distribution order by the WCS, and planning the distribution order according to the sorting detail
Generating one-to-one corresponding ex-warehouse tasks to be executed;
after a container ex-warehouse instruction corresponding to the ex-warehouse task is issued to the warehousing control system, the warehousing control system WCS dynamically shunts containers of the task according to the state of a PLC (programmable logic controller) on a line segment on the existing ex-warehouse route;
the annular line body consists of M sections of conveying lines, and each section of conveying line comprises a PLC state;
s41, the ex-warehouse task firstly carries the container to an ex-warehouse berthing platform corresponding to the current roadway through stacker equipment; a ring-shaped line body is arranged below the parking platform, and is an annular conveying line;
the berthing carrying platform is a first conveying line for taking down and placing the containers from the goods shelf by the stacker;
s42, before transferring the container flow to the annular line body at the position of the carrying platform, reading the number of the containers currently carried on the annular line body and the maximum carrying capacity of the annular line body, comparing, and finally transferring the container flow to the annular line body;
further, the step of comparing comprises the sub-steps of:
s421, if the number of containers currently carried on the ring-shaped wire body does not reach the maximum carrying capacity of the ring-shaped wire body, transferring the containers to the ring-shaped wire body;
s422, if the number of the containers currently carried on the ring-shaped line reaches the maximum carrying capacity of the ring-shaped line, the containers wait at the carrying platform until the reduction of the number of the containers carried by the line is monitored, and then the containers are continuously dispatched;
s423, continuously monitoring the warehousing task on the conveying line in the dispatching process, and if the warehousing task exists on the conveying line, executing the warehousing task by the conveying line;
by comparing the number of the containers currently carried with the maximum carrying capacity of the annular line bodies, the phenomenon that the equipment stops running, cannot run or runs out of control due to the congestion of the annular line bodies is avoided;
by continuously monitoring the warehousing tasks on the conveying line, the situation that the warehousing tasks and the ex-warehouse tasks conflict when the conveying line jointly passes through a section of conveying line to cause blockage is prevented;
s43, before the container is transported to a sorting port or a whole outlet on the annular line body, reading the PLC state of a conveying line of the sorting port or the whole outlet, and if the PLC state of the conveying line shows occupied, continuing to circulate the container on the annular line body; if the PLC state of the conveying line shows that the conveying line is idle, the containers flow to a target sorting port or a whole outlet;
the PLC state of the conveying line at the sorting port or the whole outlet is read, so that the collision of the warehousing task and the ex-warehouse task on the conveying line at the sorting port or the whole outlet is prevented, and the blockage is caused;
s5: a sorting port or a whole outlet data closed loop;
after the containers arrive at the sorting port or the whole outlet, the warehousing control system WCS monitors container in-place signals and sends container codes to the warehousing management system, the warehousing system sorts detailed records according to the container codes before matching, matched results are displayed on a screen above the sorting port or the whole outlet, and workers carry out corresponding sorting according to the content of the screen; thus, a closed loop of sorting or finishing gate data is completed.
Further, when the container reaches the sorting port or the whole outlet, the warehousing control system WCS writes the container code into the PLC offset corresponding to the sorting port or the whole outlet;
write in the container sign indicating number through storage control system WCS and sort the mouth or the whole PLC offset that the export corresponds, sort and accomplish no longer need read a sign indicating number equipment scanning container sign indicating number, press the storehouse of returning button and can return the storehouse with the container, reduced the input of equipment, facilitated the operation, promoted efficiency.
The present invention has been described in relation to the above embodiments, which are only examples of the implementation of the present invention. It should be noted that the disclosed embodiments do not limit the scope of the invention. Rather, it is intended that all such modifications and variations be included within the spirit and scope of this invention.
Claims (6)
1. A control method for automatic planning, sorting and shunting of a conveying line is characterized by comprising the following steps: the method comprises the following steps:
s1: placing a batching order, wherein the batching order comprises a batching order number, a batching type, a material name, a material code, a material batch, a sales order number, a work order number, a required quantity Qtyi and a warehouse area code; the batching order number is the order number of the batching order, and the order number is unique;
s2: matching and planning the burdening demand;
combining the same contents of the batching orders to form a batching order set;
s3: planning a container picking port or a container finishing port; planning the floor for delivering the containers and the container sorting port or the whole outlet in the sorting detail record table;
s4: sending the planning to a system and generating a warehouse-out task;
issuing the sorting detail planning distribution order to a Warehousing Control System (WCS), receiving the sorting detail planning distribution order by the WCS, and planning the distribution order according to the sorting detail
Generating one-to-one corresponding outbound tasks to be executed;
s5: sorting or finishing outlet data closed loop.
2. The method for controlling automatic planning, sorting and flow-dividing of a conveying line according to claim 1, wherein: in the step S2, the same contents of the ingredient orders mean that the material names, the material codes, the material batches, the sales order numbers, the work order numbers and the storage area codes are all the same; the order set comprises a material name, a material code, a material batch, a sales order number, a work order number, a quantity sum and a library area code; the warehouse management system also comprises an inventory material data table in the warehouse management system, wherein the inventory material data table comprises material names, material codes, material batches, sales order numbers, package codes, the quantity of materials corresponding to each package code, container codes, warehouse area codes, work order numbers, warehouse entry time, goods position codes and container codes; the package code refers to the code of the packaging box and the packaging container, and the code of each package is unique.
3. The method for controlling automatic planning, sorting and distribution of a conveying line according to claim 1, wherein: and inquiring the ex-warehouse floor corresponding to the order in the material receiving point configuration table according to the ingredient type in the sorting detail record table obtained in the step S2, and recording the ex-warehouse floor in the ex-warehouse floor corresponding to the sorting detail record table.
4. The method for controlling automatic planning, sorting and distribution of a conveying line according to claim 1, wherein: in the step S4, the sorting detail planning dispatch list is issued to the warehousing control system WCS, the warehousing control system WCS receives the sorting detail planning dispatch list, and generates one-to-one correspondence to-be-executed warehouse-out tasks according to container codes in the sorting detail planning dispatch list;
s41, the ex-warehouse task firstly carries the container to an ex-warehouse berthing platform corresponding to the current roadway through stacker equipment; a ring-shaped line body is arranged below the parking platform, and is an annular conveying line;
the berthing carrying platform is a first conveying line for taking down and placing the containers from the goods shelf by the stacker;
s42, before the containers are transferred to the annular line body at the position of the carrying platform, reading the number of the containers currently carried on the annular line body and the maximum carrying capacity of the annular line body, and performing a comparison step to finally transfer the containers to the annular line body;
s43, before the container is transported to a sorting port or a whole outlet on the annular line body, reading the PLC state of a conveying line of the sorting port or the whole outlet, and if the PLC state of the conveying line shows occupied, continuing to circulate the container on the annular line body; if the PLC state of the conveying line shows that the conveying line is idle, the containers flow to a target sorting port or a whole outlet; the PLC state of the conveying line of the sorting port or the whole outlet is read.
5. The method for controlling automatic planning, sorting and distribution of the conveying line according to claim 4, wherein: in step S42, the step of comparing includes the following sub-steps:
s421, if the number of containers currently carried on the ring-shaped wire body does not reach the maximum carrying capacity of the ring-shaped wire body, transferring the containers to the ring-shaped wire body;
s422, if the number of containers currently carried on the ring-shaped linear body has reached the maximum carrying capacity of the ring-shaped linear body, the containers wait at the parking platform until the number of containers carried on the ring-shaped linear body is reduced, and then continue to be dispatched;
and S423, continuously monitoring the warehousing task on the conveying line in the dispatching process, and if the warehousing task exists on the conveying line, executing the warehousing task by the conveying line.
6. The method for controlling automatic planning, sorting and distribution of a conveying line according to claim 1, wherein: when the container reaches the sorting port or the whole outlet, the warehousing control system WCS writes the container code into the PLC offset corresponding to the sorting port or the whole outlet.
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