CN115043120B - Efficient intelligent warehousing system and storage method - Google Patents

Abstract

The invention relates to an efficient intelligent warehousing system and a storage method, and belongs to the technical field of intelligent warehousing systems for whole vehicle parts. The multi-layer multi-storage-position system comprises a material box, a tray, a transmission medium and a storage rack, wherein the material box, the part information flow transmission and the storage rack are selected, the data intercommunication with other production systems or automation systems is realized, the multi-layer multi-storage-position mode of a single storage rack is simplified into a multi-layer single storage-position mode, and the goods are delivered according to the principle of first-in first-out, or the goods are delivered by manually specifying information. The intelligent storage system has the advantages that intelligent storage of incoming goods parts of a whole vehicle enterprise is realized with higher efficiency, the feed boxes with different sizes can be mixed and placed on the goods shelf, and various scenes are mixed and applied, people, warehouses, automation equipment, warehouses and the like, so that the waste existing in the existing intelligent storage system storage method is solved, and the intelligent storage system can be in butt joint with other intelligent equipment.

Description

Efficient intelligent warehousing system and storage method

Technical Field

The present invention relates to the technical field of intelligent storage systems for vehicle parts, and in particular to an efficient intelligent storage system and a storage method.

Background technique

At present, there are two main parts storage and warehousing modes for vehicle manufacturers:

The first is that personnel stack according to a certain storage method (progress rule or part type rule), and then plan the parts supply to the line side according to the actual production needs or supply them to the line side according to the part type according to the production line needs. This will lead to problems such as inaccurate parts storage, discrepancies between the number of parts and the actual number, failure to follow the first-in-first-out principle in the entry and exit of parts, and difficulty in counting parts, which will have a significant impact on production continuity and quality.

The second method is to use intelligent storage and establish a corresponding storage system to store parts according to a certain method, so as to achieve real-time inventory, first-in-first-out and delivery according to demand. However, the shelf storage system of the vehicle manufacturer now calculates energy efficiency and utilization rate according to whether the storage space is empty or full. That is, a shelf has n storage spaces, and no matter the size of the goods, they are stored one by one, and the utilization rate of the shelf storage space is calculated by the number of empty and full spaces. However, there are many types of parts in the vehicle factory, and the sizes of the packaging boxes used are inconsistent. This leads to the following problems in practice for this intelligent inventory system and storage method:

1) Due to the large variety of material boxes, when designing shelf storage locations, if the storage locations are designed according to the size of the material boxes, a storage location can only store a single type of material box. This results in each inventory location being calculated according to the peak value of parts storage, which results in the storage location being far greater than the actual usage, resulting in a waste of space, increased shelf costs, and increased ineffective occupancy of factory area.

2) Due to the large variety of material boxes, when designing shelf locations, if a single storage location is used (based on the largest box size), this will result in small items being moved to a larger location, and the storage location will also cause a waste of space, leading to the addition of more shelves to meet storage needs, increasing usage costs, wasting usage space, and increasing ineffective occupancy of factory area.

Summary of the invention

The present invention provides an efficient intelligent warehousing system and storage method to solve the waste problem in the existing intelligent warehousing system and storage method, with the purpose of realizing intelligent storage of incoming parts for vehicle manufacturers with higher efficiency. Boxes of different sizes can be mixed and placed on the shelves, and multiple scenarios can be mixed and applied, such as people and warehouses, automated equipment and warehouses, etc.

The technical solution adopted by the present invention is that the efficient intelligent warehousing system includes:

(1) Material box:

Use bins of sizes A, 2A, 4A, 6A and 8A, where A is a bin unit, volume = length ₁ × width ₁ × height ₁ ;

(2) Pallet

Used to hold material boxes, its length ₂ and width ₂ are respectively 4 times the length ₁ and 2 times the width ₁ ; the pallet and the material boxes on it constitute a pallet;

(3) Transmission medium

The content of electronic information stored by using a kanban or a storage chip includes at least: part information, the length, width and height of the material box used for the parts, and the number of parts in each box;

(4) Shelves

Fixed shelves and mobile shelves are used. The interlayer bottom plates of the shelves are used to place pallets, and interlayer codes are pasted on the shelves to bind the system and storage parts.

The material box of the present invention is used for containing automobile parts with a length or width of ≤1600mm and a single piece weight of ≤13KG.

The storage method using an efficient intelligent warehousing system includes the following steps:

(I) Select the material box

1) Parts Summary

Select auto parts with length or width ≤1600mm and single piece weight ≤13KG;

2) Setting of pallet standards

A pallet consists of two parts: a pallet and a material box on top of the pallet. Choose a standard pallet based on the pallet weight, the space on the transport truck, and the size of the parts.

3) Standard material box setting

The material box complies with the European standard. After the standard of the pallet is determined, it is divided. First, the smallest material box unit A is confirmed. Other standard boxes include 2A, 4A, 6A, and 8A.

(II) Parts information flow transmission method

1) The transmission medium used is set

Including a kanban sticking method or a method of using a chip to store part information IFRD;

2) Enter necessary information

The content of the stored electronic information includes at least: part information, the length, width and height of the material box used for the parts, and the number of parts in each box;

(III) Select storage shelves

Consider the size of the material box and the specific usage scenario, and select according to the unit. The inter-layer size of the shelf should take into account the universality of all types of boxes. The space within the shelf layer should be based on the selected standard pallet, and the accessibility and stacking characteristics should be considered at the same time. This can achieve more scenarios and avoid waste. Select fixed shelves and mobile shelves, and paste inter-layer codes on the shelves for binding the system and storage parts. When storing, subdivide according to the concept of "layer";

(IV) System operation method

1) Mixed storage of various parts and material boxes, one-keyboard keying, inventory visualization, and first-in-first-out of parts;

2) Data intercommunication with other production systems or automation systems can be realized, and various scenarios can be accommodated, including docking between people and warehouses, docking between automation equipment and warehouses, etc. When in use, the solution can be optimized according to actual usage needs, as well as the connection with external systems;

3) System storage method, simplifying the single-shelf multi-layer multi-storage mode to a multi-layer single-storage mode;

4) System retrieval method: according to the storage date of the parts, shipment is carried out according to the principle of first in first out, or shipment is carried out according to manually specified information.

In the material box selected in (I) of the present invention, due to the variety of parts and complex styles, the non-standard box bottom surface is consistent and the height is a variable.

In the second aspect of the present invention, if the billboard transmission method is used, a two-dimensional code is added to the billboard to store relevant electronic information.

The system storage method in (iv) the system operation method of the present invention includes:

When storing parts in boxes, first scan the kanban on the parts box or read the IFRD chip to read the name, quantity, length, width and height of the box; then put it into an empty rack. You can put it in a mixed way, but make sure it is neat; after placing it, scan the inter-layer code of the shelf, and the system records the information; the recording method is: the total volume of the single storage location design is a fixed threshold M, and the volume of the box is automatically calculated by scanning the length, width and height to obtain the volume V1, and the volumes of other boxes are V2, V3...Vn, and the utilization rate of shelf storage is N=(V1+V2+...+Vn)/M. When N≥1, it proves that the inventory of this layer is full and no more parts are accepted; when N<1, parts can be accepted;

Calculate the utilization of other layers to determine whether the inventory is full; the system sorts the utilization of all shelves and stores them according to the principle of utilization from low to high.

The system removal method in (iv) the system operation method of the present invention includes:

The system obtains the information that needs to be picked up: part name, quantity, and provides information according to the first-in-first-out principle. Then the corresponding automated equipment or personnel will take out the parts that need to be shipped according to the information provided by the inventory system, and then unbind the parts and shelves. The unbinding method can be scanning a code, sensing, etc.; after receiving the notification of taking away the parts, the system will vacate the storage location of this part, subtract the corresponding volume, recalculate the shelf storage utilization rate N, and then sort all the utilization rates in the shelf. When the next part is to be stored, the shelf with the lowest utilization rate will be given priority, thereby realizing the actual operation cycle.

The beneficial effects of the present invention are: intelligent storage of incoming parts for vehicle manufacturers can be achieved with higher efficiency, boxes of different sizes can be mixed and placed on the shelves, and a variety of scenarios can be mixed and applied, such as people and warehouses, automated equipment and warehouses, etc., thereby solving the waste existing in the storage methods of existing intelligent warehousing systems, and can be connected with other intelligent devices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a schematic diagram of the segmentation of a pallet and a standard container;

Fig. 2 is a schematic diagram of a shelf;

FIG3 is a front view schematic diagram of the system storage method;

Fig. 4 is a left side view of Fig. 3;

FIG5 is an example diagram of an existing storage method 1;

Fig. 6 is an example diagram of the method of the present invention;

FIG. 7 is an example diagram of the second existing storage method.

Detailed ways

Efficient intelligent warehousing system includes:

(1) Material box:

Referring to FIG1 , the material boxes of sizes A, 2A, 4A, 6A and 8A are used, wherein A is a material box unit, volume = length ₁ × width ₁ × height ₁ ;

The material box is used to hold automotive parts with a length or width of ≤1600mm and a single piece of ≤13KG;

(2) Pallet

Used to hold material boxes, the length ₂ and width ₂ are respectively 4 times the length ₁ and 2 times the width ₁ ; the pallet and the material boxes thereon constitute a pallet, see Figure 1;

(3) Transmission medium

The content of electronic information stored by using a kanban or a storage chip includes at least: part information, the length, width and height of the material box used for the parts, and the number of parts in each box;

(4) Shelves

Fixed shelves and mobile shelves are used. The interlayer bottom plates of the shelves are used to place pallets. Interlayer codes are pasted on the shelves to bind the system and storage parts; see Figure 2.

Referring to Figures 3 and 4, the storage method using an efficient intelligent storage system includes the following steps:

(I) Select the material box

1) Parts Summary

Select auto parts with length or width ≤1600mm and single piece weight ≤13KG;

2) Setting of pallet standards

A pallet consists of two parts: a pallet and a material box on top of the pallet. A standard pallet is selected based on the pallet weight, the space of the transport truck, and the size of the parts. Standard pallets are a necessary condition for improving the efficiency of the warehousing system. Only when pallets are standardized can the overall efficiency of the logistics system be improved.

3) Standard material box setting

The material box complies with the European standard. After the standard of the pallet is determined, it is divided. First, the smallest material box unit A is confirmed. Other standard boxes include 2A, 4A, 6A, and 8A. Of course, due to the variety of parts and complex styles, non-standard boxes will appear in order to consider practicality and economy. Even so, the design of non-standard boxes must ensure that the bottom surface is consistent, and the height is a variable;

(II) Parts information flow transmission method

1) The transmission medium used is set

Including the method of sticking on the kanban board or using the chip to store the part information IFRD method. If the kanban delivery method is used, a QR code should be added to the kanban board to store the relevant electronic information;

2) Enter necessary information

The content of the stored electronic information includes at least: part information, the length, width and height of the material box used for the parts, and the number of parts in each box;

(III) Select storage shelves

Consider the size of the material box and the specific usage scenario, and select according to the unit. The inter-layer size of the shelf should take into account the universality of all types of boxes. The space within the shelf layer should be based on the selected standard pallet, and the accessibility and stacking characteristics should be considered at the same time. This can achieve more scenarios and avoid waste. Select fixed shelves and mobile shelves, and paste inter-layer codes on the shelves for binding the system and storage parts. When storing, subdivide according to the concept of "layer";

(IV) System operation method

1) Mixed storage of various parts and material boxes, one-keyboard keying, inventory visualization, and first-in-first-out of parts;

2) Data intercommunication with other production systems or automation systems can be realized, and various scenarios can be accommodated, including docking between people and warehouses, docking between automation equipment and warehouses, etc. When in use, the solution can be optimized according to actual usage needs, as well as the connection with external systems;

3) System storage method, simplifying the single-shelf multi-layer multi-storage mode to a multi-layer single-storage mode;

When storing parts in bins, first scan the kanban on the parts bin or read the IFRD chip to read the name, quantity, length, width and height of the bin; then put it into an empty rack. You can put it in a mixed way, but make sure it is neat; after placing it, scan the inter-layer code of the shelf, and the system records the information; the recording method is: the total volume of the single storage location design is a fixed threshold M, and the volume of the bin is automatically calculated by scanning the length, width and height to obtain the volume V1. The volumes of other boxes are V2, V3...Vn, and the utilization rate of shelf storage is N=(V1+V2+...+Vn)/M. When N≥1, it proves that the inventory of this layer is full and no more parts are accepted; when N<1, parts can be accepted;

Calculate the utilization of other layers to determine whether the inventory is full; the system sorts the utilization of all shelves and stores them in order of utilization from low to high;

4) System retrieval method: according to the storage date of the parts, shipment is carried out according to the principle of first-in-first-out, or shipment is carried out according to manually specified information;

The system obtains the information that needs to be picked up: part name, quantity, and provides information according to the first-in-first-out principle. Then the corresponding automated equipment or personnel will take out the parts that need to be shipped according to the information provided by the inventory system, and then unbind the parts and shelves. The unbinding method can be scanning a code, sensing, etc.; after receiving the notification of taking away the parts, the system will vacate the storage location of this part, subtract the corresponding volume, recalculate the shelf storage utilization rate N, and then sort all the utilization rates in the shelf. When the next part is to be stored, the shelf with the lowest utilization rate will be given priority, thereby realizing the actual operation cycle.

The following is a comparative analysis of the existing technical solutions and the present invention for the scenario where the vehicle manufacturer receives multiple boxes of parts:

(1) Assume that the factory produces a maximum of 40 vehicles per day, 20 high-end vehicles per day (2 boxes of part A and 2 boxes of part B), and 20 low-end vehicles per day (2 boxes of part C and 2 boxes of part D), a total of 8 boxes, which are set according to the existing intelligent warehouse management method and the intelligent warehouse management method of this solution (assuming that they are all single-sided shelves). 1) Existing intelligent warehouse management method: Figure 5, designed according to the principle of one storage location for each part, but the production ratio of high-end and low-end vehicles will change, so the design should be based on the full production of high-end vehicles or full production of low-end vehicles. That is, 4 boxes of storage locations must be prepared for each part. Since the storage locations for parts are not universal, this leads to waste. 2) Intelligent warehouse management method of this solution: Figure 6, storage space can be universal, saving area.

When designing shelf storage locations according to the prior art, the storage locations are designed according to the size of the material boxes, which means that a storage location can only store a single type of material box. This means that each inventory location must be calculated according to the peak value of parts storage, which results in the storage location being much larger than the actual usage, resulting in a waste of space, increased shelf costs, and increased ineffective occupancy of factory area. The method of the present invention does not need to consider the inventory peak value of each part, but only the overall inventory peak value. According to the 30% model ratio change of general vehicle manufacturers and other 20% factors (safety, transportation, etc.), at least 50% of the area and the number of shelves can be saved.

(2) Assume that the factory produces a maximum of 40 vehicles per day, including 20 high-end vehicles (2 boxes of A parts and 2 boxes of B parts) and 20 low-end vehicles (2 boxes of C parts and 2 boxes of D parts), for a total of 8 boxes. They are set according to the existing intelligent warehouse management method and the intelligent warehouse management method of this solution (assuming that they are all single-sided shelves). 1) Existing intelligent warehouse management method: Figure 7. When designing storage locations, they are all designed according to the largest D parts. This can meet the changes brought about by changes in production ratios. However, there is a serious waste of space. 2) The intelligent warehouse management method of the present invention: Figure 6. The storage space can be universal, saving area.

When designing shelf locations according to the prior art, if a single storage location is used (based on the largest box size), small items will be enlarged, and the storage location will also cause space waste, resulting in the addition of more shelves to meet storage needs, increasing usage costs, wasting usage space, and increasing ineffective factory area occupation. However, the intelligent warehouse management method of the present invention does not need to consider the size of each material box, and can be mixed, which greatly reduces waste. Preliminary estimates show that at least half of the area and the number of shelves can be saved.

Claims (5)

1. A method of efficient storage of an intelligent warehousing system, the efficient intelligent warehousing system comprising:

(1) A material box:

A bin of sizes a, 2A, 4A, 6A and 8A is used, where a is a bin unit, volume = ₁ x wider ₁ x higher ₁;

(2) Tray for holding food

The length ₂ and the width ₂ of the material containing box are respectively 4 times longer ₁ and 2 times wider ₁; the tray and the feed box on the tray form a goods tray;

(3) Transmission medium

The electronic information is stored by a signboard or a storage chip, and the electronic information comprises at least the following contents: part information, length, width and height of a material box used for parts and the number of parts in each box;

(4) Goods shelf

The method comprises the steps that a fixed goods shelf and a movable goods shelf are adopted, an interlayer bottom plate of the goods shelf is used for placing a tray, interlayer codes are stuck on the goods shelf, and the interlayer codes are used for binding a system and storage parts;

the method is characterized by comprising the following steps of:

selecting a material box

1) Part summary

Selecting automobile parts with the length or width less than or equal to 1600mm and the single piece type less than or equal to 13 KG;

2) Standard setting for pallet

The pallet consists of two parts, a pallet is added with a material box above the pallet, and a standard pallet is selected according to the weight of the pallet, the space of a transport truck and the size of parts;

3) Standard bin settings

After the bin meets the European standard and the standard of a goods support is calibrated, dividing, firstly, confirming a minimum bin unit A, and other standard bins comprising 2A, 4A, 6A and 8A;

Method for transmitting part information flow

1) Transmission medium setting for use

The method comprises a signboard pasting method or a method for storing part information IFRD by using a chip;

2) Necessary information entry

The content of the stored electronic information at least comprises: part information, length, width and height of a material box used for parts and the number of parts in each box;

(III) selecting storage shelves

The size of the material box and the specific use scene are considered, the size of the interlayer of the goods shelf is selected according to the unit, the universality of all the box types is considered, the space in the goods shelf layer is taken as a reference according to the selected standard goods support, and meanwhile, the taking performance and the stacking performance are considered, so that more scene applications are realized, waste is avoided, a fixed goods shelf and a movable goods shelf are selected, interlayer codes are stuck on the goods shelf for binding a system and storage parts, and subdivision is carried out according to the concept of layers during storage;

(IV) System operation method

1) Mixing storage of various parts and a feed box, one-key inventory visualization and part first-in first-out;

2) The method realizes data intercommunication with other production systems or automation systems, accommodates various scenes, including butt joint of people and warehouses, butt joint of automation equipment and warehouses, and carries out scheme targeted optimization and connection of external systems according to actual use requirements when in use;

3) The system storage method simplifies the single-shelf multilayer multi-storage mode into a multilayer single-storage mode, and comprises the following steps:

when the part material box is stored, firstly, a sign board on the part material box is scanned or an IFRD chip is read, and the names, the number and the length, the width and the height of the material box of the parts are read; then placing the mixture into an empty material rack, and mixing the mixture when placing the mixture, wherein the mixture is ensured to be tidy; after the shelf is placed, the interlayer codes of the shelf are scanned, and the system records information; the recording method comprises the following steps: the total design volume of a single storage position is a fixed threshold M, the length, the width and the height of a bin are obtained through code scanning, the volume V1 is obtained, the volumes of other bins are V2 and V3 … … Vn, the storage utilization rate of a shelf is N= (V1 + V2+ … + Vn)/M, and when N is more than or equal to 1, the storage of the bin is proved to be full, and part receiving is not performed any more; when N is less than 1, receiving the part;

Calculating the utilization rate of other layers, and judging whether the inventory is full; the system sorts the utilization rates of all the shelves and stores the shelves according to the principle that the utilization rates are low to high;

4) The system taking-out method is to carry out shipment according to the first-in first-out principle according to the date of the part, or to carry out shipment by manually specifying information.

2. The method of claim 1, wherein the height of the selected bin is variable due to the variety and complexity of the types of parts in the bin.

3. The method for storing an intelligent warehouse system according to claim 1, wherein if the method for transmitting a signboard is used, two-dimension codes are added to the signboard to store the related electronic information.

4. The method of claim 1, wherein 4) the system extraction method of the (four) system operation method comprises:

The system obtains information of goods needing to be fetched: providing information according to the first-in first-out principle by the number of the parts, taking out the parts to be delivered according to the information provided by the inventory system by corresponding automatic equipment or personnel, unbinding the parts and the goods shelves, and scanning and sensing the unbinding method; after the notification of taking away the part is received, the system can vacate the part storage position, subtract the corresponding volume, recalculate the storage utilization rate N of the goods shelves, and then sort all the utilization rates in the goods shelves, when the next part is to be stored, the goods shelf with the lowest utilization rate is preferably selected, so that the operation and circulation in practice are realized.

5. The method for efficient intelligent warehousing system storage of claim 1, wherein: the feed box is used for containing automobile parts with the length or width less than or equal to 1600mm and the single piece type less than or equal to 13 KG.