RU2329191C2 - Multi-deck high-density cargo bin storehouse automatic control system - Google Patents

Abstract

FIELD: transportation.

SUBSTANCE: system incorporates a central computer, computers furnished in a lift, cargo truck and cargo gripping device communicating by means of a wire and a wireless means and being operated in a real-time mode. The said system is provided with safety pickups, laser range meters, transport mechanisms wheels guides mating pickups. All the said computers run their independent programs. The central computer control program operates by an algorithm of executing operations in various conditions of loading/unloading the cargo bins allowing for priorities of cargoes distribution in compliance with storage terms, load/unload job minimum time, warehousing cargo stock number series, burden of storage uniformity, as well as the cargo cell ID Number data, cargo stock number, quantity in storage units, weight, date, date of manufacture, shelf life and historical records of all operation with cargoes for the last three months. Depending upon the storehouse stock amount, the said system can incorporate at the aforesaid mechanisms up to four standby subsystems.

EFFECT: storehouse jobs optimisation.

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Description

The invention relates to means for automatically controlling a transport system in multi-tier warehouses of high-density storage of cells with cargo, for example pallets on racks.

In all the most developed countries, there is a tendency to carry out loading and unloading operations in warehouses without human intervention. This problem is being solved in two directions - the development of mechanisms working on unmanned technology, and the development of automatic control systems for these mechanisms using modern computer technology with appropriate software. The greatest achievements in the development of automatic control systems for transport mechanisms in warehouses are observed in Japan. In this country there is a significant number of patent documents reflecting developments in the field of automatic control of material handling at warehouses. Thus, for example, a method and device for managing a warehouse are known from Japanese Patent [1]. The device contains an input unit through which information containing the place of dispatch of goods, the cost of the goods sent, a memory unit that stores information entered through the input unit, a command generation unit that reads information from the memory unit and generates control commands in accordance with the read information, is operational a unit that sets the first priority for unloading goods in accordance with the value of the goods sent and sets a second priority for unloading, determined in accordance with the number HONORS days unloading and the number of working days and adds the data to the read information; an indicator that displays control information, a control unit that selects, in accordance with the first priority, the control information displayed on the indicator, and corrects the selected control information in accordance with the second priority. However, the considered system of automatic warehouse management cannot be used on complex transport systems of storage facilities, the task of which is to load and unload cells with cargo, taking into account the choice of the optimal location for installing cargo in the warehouse based on the minimum loading time, uniform distribution of cargo to the rack structures , the uniformity of their placement, as well as taking into account the shelf life and demand for goods. In addition, the control system must perform the task of archiving all operations of the transport system. In complex transport systems of storage facilities that have simultaneously operating duplicate mechanisms that can serve any place of cargo placement, reliability increases many times, but there is a need to place individual computers on all transport mechanisms. All this leads to the need to develop a system for automatic warehouse transport management with new approaches, which were later implemented in the automatic warehouse management system presented below.

The applicant (LLC MNPP Saturn) has developed a transport system for storage facilities that operates using unmanned technology in multi-tier warehouses of high-density storage of pallets with cargo on racks [2]. This transport system includes a hoist, mechanisms of horizontal both direct translational-reciprocal and perpendicular translational-reciprocal movement of the cells with cargo, made in the form of a cargo trolley and a freight hook, which move on wheels along the guides and contain reels with cable. In addition, the loader has a chain mechanism, and the hoist, cargo trolley and loader can simultaneously be located in all corner parts of the warehouse and mutually duplicate all cargo operations in the warehouse. For this transport system, the inventive automatic transport control system for a warehouse of high-density storage cells with cargo, for example pallets on racks, has been developed.

The closest analogue of this system, adopted as a prototype, is the application of the United States [3]. This application presents an automatic control system for the transport system of a warehouse of a high-density placement of cells with cargo on tiered racks. This transport system has a lift and mechanisms for horizontal movement of the cells with the load both in the forward translational-return and in the perpendicular translational-reverse direction. The automatic control system of this transport system contains a central computer connected by a network with computers of horizontal movement mechanisms, in the memory of which the terminal number (storage location), where the cargo is located, the name of the parts and their designation, date and time of receipt, date and time of delivery of the cargo are entered. The memory of the central computer stores the program for managing computers of horizontal movement. The disadvantages of this automatic control system include, first of all, the need to have a large number of computers with which it is necessary to equip each storage location of a cell with cargo (paragraph 0083 of the application description). A significant drawback of this system is that it can only function if 10-20% of the compartments (storage locations) should be allocated for the so-called "hidden compartment", i.e. under compartments for maneuvering when moving cells with cargo (paragraph 0080 description). The lack of reliability of the entire control system should also be attributed to a disadvantage, when the failure of a computer of horizontal movement essentially leads to the inaction of the computers around it, because all teams go sequentially between them. In addition, for mechanisms moving in space, it is necessary to have safety devices (sensors), accurate orientation devices that prevent the occurrence of emergency (emergency) situations. Therefore, the applicant was faced with the task of developing an automatic control system that would not have the indicated drawbacks and was able to control the transport system developed by the applicant [2]. Thus, the following should be attributed to the technical result that should have been achieved in the development of the automatic transport control system for a multi-tier high-density storage cell with cargo, for example pallets on racks. First of all, the system should provide such a management of warehouse transport, in which the filling of the storage space would be the greatest, taking into account the choice of the optimal location for the installation of cargo in the warehouse, based on the minimum loading time. At the same time, the automatic control system should be reliable due to duplication of control of the mechanisms of vertical and horizontal movement of the cells with the load, as well as the use of safety sensors and precise orientation devices. To enhance reliability in the mechanisms of vertical and horizontal movement of goods should be placed such computers (controllers), which would be equipped with individual control programs of these mechanisms in real time. In addition, the central computer management program should contain archived data on all cargo operations for the last three months.

The automatic control system developed by the applicant (LLC MNPP Saturn) for the transport of a multi-tier warehouse of high-density storage of cells with cargo, for example pallets on racks, is described below.

Figure 1 presents a block diagram of an automatic control system; figure 2 is a block diagram of a computer lift; figure 3 is a block diagram of a computer freight truck; figure 4 is a block diagram of a computer of the loader; figure 5 - algorithm for performing automatic control operations in a central computer; Fig.6 is a continuation of Fig.5; figure 7 - algorithm for the operation of automatic control in the computer of the lift; on Fig - algorithm for the operation of automatic control in the computer of a freight truck; figure 9 is a flowchart of automatic control operations in the computer of the load.

The automatic transport management system for a multi-tier high-density storage unit for cells with cargo, for example pallets on racks, has been developed with reference to the transport system of a high-density long-level cargo storage on pallets described in the Warehouse Complex magazine [2].

The automatic control system shown in FIG. 1 includes a central computer 1, from one to four possible directions (a, b, c, d) of wired connection 2 with a lift computer 3, each of which has a wireless connection 4 with a truck 5 computer , as well as the wireless connection 6 of the latter with the computer of the loader 7. All computers are provided with specially designed programs.

The elevator computer 3 contains (Fig. 2) a processor 8, RAM 9 (random access memory), ROM 10 (read-only memory), which are connected to the elevator engine 11, sensors 12, 13 and 14, respectively, for determining the tier, the alignment of the guides, determine the load on the lift, and also receive information from the central computer 1 via wired connection 2. Between the lift computer 3 and the truck computer 5 there is a wireless connection 4.

The computer of the freight trolley 5 consists (Fig. 3) of the processor 15, RAM 16 (random access memory), ROM 17 (read-only memory), which are connected to the engine 18 of the freight trolley, laser range finder 19, sensors for aligning the guides 20, security movement 21, detecting the cell with the load 22, the security of the cable tension of the drum 23. In addition, between the computer of the cargo truck 5 and the computer of the loader there is a wireless connection 6. With the central computer 1, communication is provided through wireless ligature 4, lift computer 3 and wireline connection 2.

The computer of the loader 7 consists (Fig. 4) of the processor 24, RAM 25 (random access memory), ROM 26 (read-only memory), which are connected to the engines of the loader 27, a laser range finder 28, safety sensors 29, cell detection with 30, security of cable tension of the drum 31, security of the chain mechanism 32, security of the location of the cargo 33, as well as feedback from the central computer 1 via wireless communication 6 and 4, computers of the cargo truck 5, lift 3 and wired with ligature 2.

Automatic transport control system of a warehouse of high-density storage of cells with cargo, for example pallets on racks, works as follows.

Consider first the algorithm for performing automatic control operations in the central computer 1 (figure 5). The operator at the control desk (not shown) enters into the central computer 1 data about the cell with the load, which must be placed in the warehouse or shipped from the warehouse. Such data include: the identification number of the cell with the cargo (pallet), on which either the goods are loaded or must be loaded, the product code (article), the quantity in storage units, the weight of the cargo, production date, and shelf life. After entering the “loading” or “shipping” command (control level 1 or in abbreviated form - Art. 1), the central computer 1 evaluates the turnover of the loaded goods according to the statistical data for this goods for a period of up to three months. In addition, the central computer 1 calculates the position of the goods in the storage zone according to the criteria (Article 2): the minimum time for the operation, the uniformity of the storage of goods by code (article), the shelf life, the uniform load of the shelf structures, the article turnover statistics for a given time interval , the minimum number of permutations of cells with a load. In article 3, the central computer 1 analyzes which command came from the dispatcher: “shipment” - (yes) or “loading” - (no). If a “shipment” command is received (yes), then the execution of the command proceeds to step 4. If the command “download” (no) has been received, then the execution of the command proceeds to step 5. In step 4, the central computer 1 performs the formation of the sequence of shipment of goods according to the criterion of the minimum total time of shipment of the entire batch of articles, after which the process of executing the dispatcher command proceeds to step 5. At this control stage, the optimal choice of the number of transport subsystems and the determination of specific transport subsystems (a, b, c, d) are performed to perform the cargo operation by the criterion of the minimum time of the cargo operation. Then the process proceeds to Article 6, where it is determined which particular vehicle will be involved in the “loading-shipment”, and these subsystems are tested for their performance. At art. 7, the health of transport subsystems is assessed: if the transport subsystem is operational, the process goes to st. 8, if not, then it returns to st. 5 and the cause of inoperability is analyzed using a special subroutine, which is then eliminated. At article 8, teams are formed to carry out a cargo operation to “load-ship” a cell with cargo by specific transport subsystems (a, b, c, d). It should be borne in mind that, at certain intervals (for example, after 200 milliseconds), the central computer 1 polls all the transport subsystems about their condition and what operation they perform and at what control level they are.

Next, we consider the implementation of the automatic control system "load-shipment" on the example of one transport subsystem, for example, "a", which includes a lift computer 3, wireless connection 4 lift computer 3 with a truck computer 5, wireless connection 6 of the latter with a computer 7.

At step 9, the central computer 1 gives via wired connection 2 the start of cargo operations to the computer of the elevator 3 of the transport subsystem. At Art.10, the control of the operation of raising and lowering is carried out. The elevator computer 3 at st.14 turns on the engine 11 and performs the “raise-lower” operation, being guided by the sensors for determining the tier 12, the alignment of the guides 13, the determination of the load on the elevator 14, precisely aligning the guides for the wheels of the cargo trolley with the alignment sensor 13. At the .11, if the operation is not completed, then the control process proceeds to step 12, where the error number is determined and on step 13 the analysis of the causes of this error is made, and then return to step 10. If the control operation at Art.11 is completed, then the signal from the elevator computer 3 about the completion of all operations is sent via wire communication to computer 1, from which the command follows first via wire communication 2, and then wirelessly 4 to the computer of the cargo truck 5 to continue performance of work (Article 15, Article 19, Article 20). The computer of the cargo truck 5 turns on the engine 18 and, according to the laser range finder 19, precisely sets the cargo truck at the desired storage rack, also focusing on the sensors for aligning the guides 20, the safety of movement 21, the detection of a cell with the load on the cargo carriage 22 and the safety of the cable tension of the drum 23. At .16 the computer control operation of the cargo truck 5 is completed or not (Art. 20). If the operation is not completed, then control proceeds to step 17, where the error number is detected, then analysis is performed on step 18 and the control process returns to step 15. If the operation in Art.16 is completed, then the computer of the freight truck 5 (Art.20) wirelessly 4, through the computer of the elevator 3 (Art.19) and then via wired communication 2 gives a signal to the central computer 1 about the completion of the control program. At the next polling session, the central computer 1 sends, according to the above communication chain, a signal about the operation to the load control computer 7 and the control process goes to st.21 and further to st.25, st 26 and st.27.

The computer of the loader 7 includes the engines of the loader 27 and, according to the laser range finder 28, accurately sets the loader at the place of unloading and loading of goods, also focusing on the sensors for moving safety 29, detecting a cell with cargo on the loader 30, the safety of cable tension of the drum 31, the safety of the chain mechanism 32 and safety the location of the cargo 33. If it is necessary to put the cell with the cargo on the rack, then the computer of the load capturing device 7 includes a chain mechanism and the wheels of the load catching device for unloading, and if ogruzit on gruzozahvatchik, the chain mechanism and wheel gruzozahvatchika begin to work in the other direction. The loading and unloading operation at Article 22 is considered by the loader computer 7 in two versions: if the operation is not completed, then the error number is displayed on article 23, then on article 24 an analysis of this error is made and, by decision of the operator, the control process returns to art. 21. If there is no error, then at step 28 it is checked whether the STACK of operations is empty. If not, then the control process returns to step 10, if so, then the control process ends with notification of the central computer 1 via wireless connection 6, 4, wired connection 2 about performing management tasks.

The following describes in more detail the algorithms for performing automatic control operations in the computers of the lift 3, the cargo trolley 5 and the loader 7.

Consider the algorithm for performing automatic control operations in the computer of the lift 3 (Fig.7).

A command is sent from the central computer 1 via wired connection 2 to begin work, which is determined by the elevator computer in article 29. In Art. 30, if the status of the operation is expressed by the word “yes” (the cargo operation is performed or completed), the control process moves to Art. 38, when the wire status message 2 receives a message about the status of the cargo operation via the central computer 2. In this case, the operator decides on further actions. If the status of the freight operation is characterized by the word “no”, then the control process moves to st.31. At this stage of control, it is determined which transport mechanism the team is intended for. If it is intended for the computer of the cargo truck 5 or the loader 7 (no), the control process proceeds to step 32 when the wireless command 4 arrives at the computer of the cargo truck 5. If the command for the cargo operation relates to the computer of the lift 3 (yes ), then control passes to st.33, where the settings of the engine of the elevator 11 for raising and lowering from the ROM are read. Management passes to Art. 34 and a start (start of work) is given to the engine of the elevator 11 to perform the cargo operation. If, during the movement of the elevator, the tier 12 detection sensor has been triggered, then the operation proceeds to Art. 36, and if not, then to Art. 37, where the error number (its status) is determined and information about this is transmitted to the controller (art. 38), which decides on further actions. On st.36 reveals whether the sensor alignment guides 13. If this sensor worked, then for the computer lift 3, the process ends and this is information on wired connection 2 to the central computer 1 (st.38). If the sensor for joining the guides 13 did not work, then on st.37 the error number (its status) is determined and information about this is transmitted to the console to the dispatcher, which determines further actions.

The algorithm for performing automatic control operations in the computer of the freight truck 5 is as follows (Fig. 8). A start is given to the beginning of cargo operations via wireless line 4 and this is determined in article 39 by the computer of the cargo trolley. Then, at st.40, the cargo operation status command is determined. If the status command is characterized by the definition (yes), then the process of executing the command is moved to step 49 and a message about this is transmitted wirelessly to the elevator computer 3. If the status command is characterized by the definition of "no", the process of its execution goes to step 41 . At this stage, it is analyzed whether the team is intended for a freight trolley. If not, the control process proceeds to Art. 42, where the command is sent wirelessly 6 to the computer of the load handler 7. If the command is designed to move the cargo trolley, the control process proceeds to Art. 43. The start of the freight operation (Art. 44) is given and the freight trolley begins to move. If the sensors (st.45) of the safety of movement 21, the safety of the cable tension of the drum 23, the detection of the cell with the load 22 have worked, then the control process goes to st.48, where the error status and its number are detected, and then this information goes to the central computer 1 wirelessly 4 through the computer of the lift 3 and then through a wired connection 2. According to this information, the dispatcher makes a decision on troubleshooting. If these sensors did not work, then the control process moves to st. 46, where the desired rack is determined by the signal of the laser range finder 19. If the laser rangefinder does not work, the control process also goes to step 48 (see steps above). At step 47, the response of the rail alignment sensor 20 is detected. If this sensor does not work, the control process moves back to step 48 with actions similar to those described above. If the sensor has worked, then the control process proceeds to step 49, on which information about this goes to the computer of the lift 3 via wireless communication 4 and then to the central computer 1 via wired connection 2. This completes the control process of the computer of the freight truck 5.

Consider now the algorithm of automatic control operations in the computer of the loader 7 (Fig.9). After passing the command from the central computer 1 through the computer of the lift 3 and the computer of the cargo truck 5 to the computer of the load handler 7 wirelessly 6, the program for managing the cargo operation starts (st. 50). The invader receives a command to carry out the operation for the delivery of goods (Article 51). If the command does not pass to the engines of the loader 27, the control process proceeds to st.57, where the error status and its number are detected, and then this information goes (st.58) to the central computer 1 via wireless communication 6 and 4 through computers of the cargo truck 5 and lift 3, and then over wired connection 2. Based on this information, the operator makes a decision on troubleshooting. If the command to the engines of the loader 27 passes, the control process proceeds to step 52, where the settings of the engines of the loader 27, the laser range finder 28 for moving from the ROM are read. Then the control moves to st. 53, which starts the cargo operation and the engines of the loader 27 start working. If at that time the sensors for moving safety 29, detecting the cell with the load 30, the safety of the cable tension of the drum 31, the safety of the chain mechanism 32 and the safety of the arrangement cargo 33 (Art. 54), the control process proceeds to Art. 57, where the error status and its number are detected, and then this information goes (Art. 58) to the central computer 1 wirelessly 6 and 4 through computers of the cargo truck 5and lift 3, and then over wired connection 2. Based on this information, the operator makes a decision on troubleshooting. If these sensors did not work, the control process proceeds to step 55, when the loader is installed at the desired cargo storage location using the laser range finder 28. If the signal from the laser range finder 28 is not received at the end of this operation, the control process proceeds to step 57 (process control further see above). If a signal from the laser range finder 28 has been received, the control process proceeds to step 56, when the location of the load on the pickup is determined by the cell detection sensor with load 30. If there is no cargo on the loader, control passes to Art. 57 (control process, see above). If the cargo is located (Art. 58) on the load handler (yes), then the status signal of the cargo operation is transmitted to the central computer 1 via wireless communication 6 and 4, through the computers of the cargo trolley 5 and elevator 3, and then through wired connection 2. After that, the computer Loader 7 starts to wait from the central computer 1 for a new command.

Information sources

1.JP 3490301 B2, 2000053218 A.

2. Warehouse automatic system "Intelligent Warehouse" (IP). Magazine "Warehouse complex" No. 2, March 2006, pp. 20-26.

3. US 2005/0186053 A1.

Claims (1)

Automatic transport control system of a multi-tier warehouse of high-density storage of cells with cargo, for example pallets on racks including a lift, horizontal mechanisms for both direct translational-reciprocal and perpendicular translational-reciprocal movement of cells with cargo, containing a central computer with a transport control program for wired communication, computers of mechanisms of horizontal movement with a program for their management, as well as sensors for detecting cells with cargo on mechanisms of horizontal ontal movement, characterized in that it further comprises a lift computer with a control program, wireless serial communication devices, laser rangefinders, sensors on the lift to determine the load, tier and alignment of the guides for the wheels of the horizontal movement mechanisms, made in the form of a cargo trolley and a loader moving in the guides perpendicular to each other, and the elevator, the cargo trolley and the loader are made with the possibility of simultaneous placement in all angles the new parts of the warehouse and mutual duplication of loading and unloading operations, as well as safety sensors for moving, positioning the cargo, cable tension of the drum, chain mechanism, located on the cargo trolley and the freight hook, while the central computer program contains an algorithm for performing operations for various loading situations - unloading cells with cargo, taking into account the criteria for priority delivery of goods by storage periods, the minimum time for operations, the uniformity of cargo storage in ar ikul, uniformity of warehouse load, as well as information on the identification number of the cell with the cargo, its article number, number in storage units, weight, production date, expiration date and archive data on all operations with the cargo for the last three months, while the lift computer control program contains an algorithm of operations for receiving a signal from a central computer via wire communication to raise and lower a cell with a load to the desired tier using the sensors for detecting the load, tier and alignment of the guides and transmitting a signal and wirelessly to the computer of the truck, the control program of which includes the algorithm of operations to deliver the cell with the cargo to the desired rack according to the signals of the laser range finder located on the truck, the sensors for aligning the guides, the safety of movement, the safety of the cable tension of the drum, as well as the signal transmission wireless connection to the computer of the invader, and the control program of the computer of the latter contains an algorithm of operations for the delivery of cells with cargo to the storage location on the stell also by the laser range finder located on the pickup, movement safety sensors, load location, chain mechanism, load cell detection sensor, as well as by sending a signal on the performance of all operations through the wireless and wired communication system to the central computer.

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