自动化立体仓库仓储管理系统的设计与实现

仓储管理系统（WMS）是用来管理仓库入/出库作业、库存、订单和设备的应用软件系统.本文以某公司自动化立体仓库仓储管理系统为背景,结合国内外自动化立体仓库的发展现状,对自动化立体仓库系统软硬件结构及其关键技术进行了深入的研究和探讨,提出了自动化立体仓库仓储管理系统的总体框架和详细设计解决方案,通过计算机完成统计、查询、分配货位、数据备份、交易比对等工作,有效提高了仓库运行效率40％以上,同时还缩短了企业供货时间,降低了企业生产成本.     

A simulation modeling framework for multiple-aisle automated storage and retrieval systems

This paper presents a simulation model framework for unit-load automated storage and retrieval systems (AS/RS) able to cope with most of the features found in industrial settings like, for example, multiple aisles, non aisle-captive cranes or double-deep unit-load AS/RS. Although these features characterize most of the industrial applications, they have been simply neglected by most of the previously published research oriented papers, which explains at least partially the low impact of the research output in practice. To help mitigating this drawback, this paper first presents an up-to-date chronological literature survey, which includes works that use any form of simulation in the modeling process. It then proposes an Object-Oriented Simulation Model for unit-load AS/RS developed with a purely generic mindset. In this model, the physical design decisions are separated from the operational decisions, which makes it possible, first, to obtain a better understanding of AS/RS dynamics and, second, to increase the model’s flexibility and generality, thus allowing many interesting scenarios to be represented. In particular, the simulation modeling framework has been used to develop a simulator and to conduct a preliminary study on a multi-aisle AS/RS.     

Travel time analysis of a new automated storage and retrieval system

In conventional automated storage and retrieval systems (AS/RS), stacker cranes are used to access (store or retrieve loads into/from) the storage cells. The stacker cranes can travel simultaneously in the vertical and horizontal directions. However, because the combined motions generally require heavy machineries, the stacker cranes are inadequate for extra heavy loads such as sea container cargo. For such applications, we present a new kind of storage/retrieval (S/R) mechanism, designed with input from AS/RS manufacturers. Unlike stacker cranes, the new S/R mechanism has one vertical platform and N horizontal platforms to serve N tiers of an AS/RS rack. The vertical platform provides the vertical link among different tiers of the AS/RS rack, whereas the horizontal platforms access the storage cells on a given tier. The vertical platform and the horizontal platforms may move independently and concurrently; and the separation of the mechanisms for vertical/horizontal movements also makes the platforms lighter and hence they can operate at a higher speed than the conventional design. We then present a travel-time model under the stay dwell point policy, i.e. the platforms remain where they are after completing a storage/retrieval operation. The model is validated by computer simulations. The results show that our analytical model is reliable for the design and analysis of the new kind of AS/RS. We also present guidelines for the optimal design of a rectangular-in-time AS/RS rack with the new S/R mechanism.     

Load shuffling algorithms for split-platform AS/RS

Although automated storage/retrieval Systems (AS/RS) allow random access to any storage cells, often it is advantageous to pre-sort the loads to minimize the retrieval time. In this paper, we address the issue of load shuffling on a new type of AS/RS (i.e., the split-platform AS/RS), which have separate and independent mechanisms for horizontal and vertical movements. We present the shuffling algorithms for such AS/RS, and analyze the required shuffling time and retrieval time. Results from these analysis and numerical experiments show that the shuffling algorithms presented are indeed quite efficient.     

自动化仓库管理与控制系统集成设计与实现

分析了自动化仓库管理与设备控制系统的功能需求，指出了它与过程监控系统的不同点，划分了自动化仓库管理与控制系统功能模块。结合以太网和现场总线的技术特点，设计了以交换式快速以太网为主干、以总线型现场总线为底层的系统集成网络结构，给出了基于以太网的设备监控通信协议分层模型。通过介绍该设计在某企业生产仓储兼有物流功能的自动化仓库的实现，阐明了仓库管理与监控系统软件的集成。该设计使用通用器件和通用技术以较低成本实现了自动化仓库管理与控制系统集成，具有易于扩展和维护的优点。     

PLC在立体仓库自动控制系统中的应用

自动化仓库是在不直接进行人工参与的情况下，自动地存储和取出物料的系统。文章通过对自动化立体仓库的运行过稃和功能要求的分析，确定合理的控制原则，提出具体的控制方法，运用FPWIN GR软件编写控制程序，通过键盘输入指令实现PLC对自动化立体仓库进、出货的手动／自动控制。     

输送机控制系统在自动化立体仓库中的应用

作为立体仓库的重要组成部分,输送机设备发挥着越来越重要的作用。仓库中所有货物的入库、出库等作业都必须通过输送机来完成。以某空港配餐公司自动化立体仓库为例,介绍了输送机在仓库中的应用,在立体仓库出入库工艺流程的基础上,分析设计了全自动模式下输送机出入库的步进流程图,并对不同工作模式下输送机的工艺流程进行了分析。     

An operation analysis of movable rack type AS/RS by use of system simulator

We perform the operation analyses of movable rack type AS/RS which is built in among manufacturing resources. Processing time and processing cost to handle each pallet are investigated. We employ the system simulator approach for the analyses. It is clarified that, if the operation conditions such as the speed of the stacker crane and/or rack are properly adjusted, the processing time of each pallet is not so increased in comparison with that in the fixed rack type case. Further, under our assumed conditions concerning the investment, we found that the cost performance of the movable rack type AS/RS accompanied with medium speed stacker crane is comparable with that of the fixed rack type AS/RS equipped with high speed stacker crane.     

一种新型电子胶带秤控制仪表的设计

针对传统的电子胶带秤控制仪表采用单片机实现累积运算,存在闭环控制效果差、通信功能不强等问题,提出了一种基于ARM的电子胶带秤控制仪表的设计方案,详细介绍了该仪表的硬件及软件设计。该仪表由数据采集器和基于ARM的显示控制器组成,采用分离式的仪表结构形式,数据采集器安装在现场,显示控制器安装在监控室,两者通过RS485接口通信。实验结果表明,该仪表的计量精度优于0.2%,设计合理。     

用PLC实现中型立体仓库控制

提出了一种用PLC实现中型立体仓库自动控制方法。立体仓库系统的运行表明堆垛机三维定位控制精确,运行可靠。     

双伸位堆垛机系统调度的优化设计

以某机务段段修配件自动化立体仓库(AS/RS)为例,通过分析影响双伸位堆垛机系统运作的重要因素,提出一种基于作业时间最短的优化设计,建立相应的数学模型,并采用分区平均搜索初始种群的遗传算法对其进行验证。结果证明该优化设计有利于提高双伸位堆垛机AS/RS系统的运作效率。     

双伸位堆垛机系统调度的优化设计

以某机务段段修配件自动化立体仓库(AS/RS)为例,通过分析影响双伸位堆垛机系统运作的重要因素,提出一种基于作业时间最短的优化设计,建立相应的数学模型,并采用分区平均搜索初始种群的遗传算法对其进行验证。结果证明该优化设计有利于提高双伸位堆垛机AS/RS系统的运作效率。     

校车滞留儿童检测系统的研究

随着越来越多的儿童选择坐校车,儿童因滞留在校车内出现意外时有发生。为防止儿童滞留在校车内,设计了一种校车滞留儿童检测系统。系统采用STM32单片机作为控制模块,在校车的车门处安装了两组红外对管和一个数码管作为计数模块,在车内安装了人体热释电传感器和面式压力检测传感器作为检测模块,并以SIM900A为主要装置的报警模块。此系统在启动和停驻时都具有检测装置。通过实物模拟,此系统达到了要求。     

A STATISTICAL MODEL FOR EXPECTED CYCLE TIME OF SP-AS/RS: AN APPLICATION OF MONTE CARLO SIMULATION

The elimination of international trade barriers, lower tariffs, and shifting centers of global manufacturing and consumption leads to new dynamics in intermodal shipping. Advanced technologies, and in particular, automated storage/retrieval systems (AS/RSs) for designing high-capacity automated container terminals, have been recently proposed as possible candidates for improving the terminal's efficiency and meeting the challenges of the future in marine transportation. In this article, the authors present an analytical statistical model for computing expected cycle time of split-platform AS/RS (SP-AS/RS), in order to reduce average handling time of this system. The accuracy of the proposed statistical model is validated by Monte Carlo simulation. The results show that the analytical model is reliable for the design and analysis of the SP-AS/RS.     

MLATSO: A method for task scheduling optimization in multi-load AGVs-based systems

In the context of increasingly competitive intelligent manufacturing, the multi-load Automated guided vehicles (AGVs) based Automated Storage and Retrieval System (AS/RS) has been of particular interest, as reductions in the number of AGVs required can significantly decrease potential congestions and increase the system effectiveness. In comparison with the single-load AGVs system, more difficult and critical issue of scheduling multi-load AGVs to automate storage/retrieval missions and to maximize economic benefits remains unresolved. Therefore, we propose a task scheduling optimization method for multi-load AGVs-based systems, with which, the objectives of least number of occupied AGVs, shortest travel time and minimum conflicts can be met simultaneously. The experiments are conducted in various scenarios, and verify that our work can use fewer AGVs to optimize tasks delivery, which enables the AS/RS stakeholders to reach win-win results for system performance and AGVs investment, thus maximizing economic benefit.     

基于iFIX的立体仓库监控系统设计与实现

针对立体仓库控制与管理自动化的需要,充分利用GE智能平台的技术优势,介绍了基于iFIX和PACSystems的立体仓库监控系统的总体结构,并重点阐述了监控系统的通信配置和组态监控系统程序设计与实现的过程及方法;本监控系统实现了对立体仓库现场设备的实时监控与管理;系统结构简单、实时性好、颇具灵活性;系统界面友好,能逼真观察系统运行过程,实用性较强;同时提供历史数据和报警信息查询,满足系统自动控制与管理的要求,具有一定实用价值;该系统具有开发周期短、可靠性高、功能完善和可视性好等优点。     

An integrated model for the design of end-of-aisle order picking system and the determination of unit load sizes of AGVs

In this paper, we deal with an assembly line production system in which an automated guided vehicle (AGV) delivers parts to each workstation of assembly lines from a miniload automated storage/retrieval system (AS/RS). Each assembly production line is characterized by a sequence of workstations linked together for the production of a given type of product. We consider simultaneously the design problem of miniload AS/RS and the problem of determining a unit load size of the AGV. First, a non-linear mathematical model is formulated under a proposed AGV dispatching policy. And then, we determine an appropriate sequence of lines of the vehicle visits. Finally, based on the characteristics of the objective function and feasible region of the decision variables, a heuristic solution procedure is developed to find a near optimal solution. To examine the validity of the model, an example problem is solved.     

Free balancing for a shuttle-based storage and retrieval system

Shuttle-based storage and retrieval systems (SBS/RSes) – a type of automated storage and retrieval system (AS/RS) – have recently been developed to increase throughput capacity. An SBS/RS can increase throughput by using multiple shuttles as storage and retrieval machines (SRMs), while traditional AS/RSes are limited because they use a single stacker crane as an SRM to handle multiple jobs. However, when setting up an SBS/RS, a significant investment is required to integrate a shuttle for each tier in the storage construction. To lower costs, a reduction in the number of shuttles is an adequate solution if the SBS/RS can maintain the designated throughput. However, this could also lead to operational problems. Namely collision prevention and workload balances could be affected because each shuttle would be able to travel to any tier for pickups and drop-offs. Thus, shuttle position control is important when the system operates with a mismatch between the number of shuttles and tiers. Ideally, free balancing should be achieved. When free balanced, each shuttle's position is monitored to prevent collisions or blockages, as well as to make sure jobs are evenly assigned and the required throughput is maintained. This paper suggests system controls to prove the effectiveness of free balancing, and it runs a simulation analysis to verify the system with the suggested controls. As a result, free balancing shows better performances in terms of throughput and utilization compared to a basic system control. Specifically, in our case, free balancing can achieve targeted throughput with less number of shuttles.     

Simulation modelling of a narrow aisle automated storage and retrieval system (AS/RS) serviced by rail-guided vehicles

A computer simulation model of an Automatic Storage and Retrieval System (AS/RS) consisting of 5 storage conveyors, 5 retrieval conveyors, 2 bi-directional conveyors, 2 order-picking stations, 7 narrow-aisle cranes and 9,310 storage locations, was created in ARENA^TM version 1.1. Rail-guided vehicles move material to and from the storage racks. The computer simulation model of the AS/RS was used to examine the operational logic of the entire system in order to determine the operational deployment strategy that yields the optimal number of rail-guided vehicles (RGVs), the utilisation of the narrow-aisle crane and also the maximum throughput of the system. This paper reports on the results of running the simulation model. For example, increasing the capacity of the storage and retrieval conveyor from 1 to 2 effectively reduces the number of RGV deadlocks by about 94%. A change of the topology of the RGVs' from 1-zone to 2-zone yielded a slightly better part retrieval time and also a reduction in the optimal number of RGVs from 5 to 4. Under these conditions, the number of storages/retrievals is about 430. The maximum throughput of AS/RS is estimated to be about 33 items per hour. The best retrieval time per part is almost 1205 seconds. As it stands, the system could do with less retrieval stations and narrow-aisle cranes which are under-utilised.     

Portable software for connecting remote microcomputers and a central minicomputer

A number of programs which allow communication between remote microcomputers and a central computing centre are described. The software is written in BASIC for the microcomputer (an Equinox) and in PASCAL for the min-computer (Nord 100). The requirement for the microcomputer to run the software is that it is CP/M-based and has a spare RS232 port. Data is transferred in blocks of 40 byte to the remotes sites via modems through the telephone lines. The datarate is 300 baud. Examples of the communication software are given.