In conventional warehouses, material handling largely relies on manual operations, resulting in low efficiency and unreliable accuracy. Especially in large-scale, multi-category storage environments, conventional manual warehousing methods have been difficult to meet the material circulation needs of modern manufacturing enterprises for "high efficiency, high precision and low labor".
Wecon launched" Box-type Warehouse Robot intelligent warehouse bus control solution", through close cooperation with AGV (Automatic guided vehicle), visual positioning, and intelligent control system, it enables rapid, precise, and automated material handling, helping enterprises build efficient, secure, and intelligent modern warehouses.
At present, the solution has successfully deployed in JD Cloud Warehouse, and demonstrate excellent efficiency and stability in complex, large-scale, multi-SKU warehousing scenarios.
Solution introduction
01 Solution configuration
This solution consists of multiple products independently developed by Wecon, including: ig series IoT HMI, AC60 series bus PLC and VD5L series bus servo system, at the same time, it integrates a camera vision system and establishes wireless communication with the warehouse server through a built-in wireless router in the electric control cabinet.
The Box-type Warehouse Robot connects to the warehouse management system through the wireless network, receives inbound/outbound instructions, and cooperates with the AGV (Automated guided vehicles) to achieve full-process automation from task reception to positioning and handing, improving the warehousing efficiency and intelligence level greatly.
02 Workflow
1. Task reception and analysis
The warehouse management system issues instructions through the wireless network, and the PLC confirms the task type and verifies the material information after parsing, judges whether to measure the box size if necessary.
2. Track-guided positioning and movement
The robot obtains the current position according to the barcode recognized by the camera, calculates the movement speed and deceleration distance through the built-in control algorithm, and moves to the target position quickly and accurately along the track, ensuring smooth movement without shaking.
3. Material handing operations
After reaching the target point, the robot automatically performs picking or placing actions. If the task involves AGV transfer, the robot can choose whether to measure the size of the shoebox according to the instructions and feed the data back to the server.
4. Data feedback and task completion
Position and status data throughout the operation process are uploaded to the warehouse server in real time for monitoring and scheduling. After completing the task, the robot waits for the next instruction to realize unmanned continuous operation.
03 Positioning method description
To ensure precise positioning during high-speed operation on the track, the system uses the camera to recognize the barcode and obtain the current position. The PLC communicates with the vision system through the custom TCP/IP protocol, analyzes the position information in real time, and calculates the best motion path based on the acceleration and deceleration curves, effectively preventing overshoot and track slippage, and achieving both high speed and high precision.
Advantages
This method not only improves the overall operation efficiency, but also ensures the accuracy of the picking and placing action, the error is controlled within ± 0.5 mm, suitable for working scenarios that require extremely high accuracy.
04 Engineering screen
Solution advantage
1 Rich functionality
The box recognition and size reporting can be enabled as needed, making it adaptable to a variety of business scenarios.
2 Strong adaptability
It supports a variety of material specifications and container types, with the self-correcting ability to fix tilting during AGV transport, making it highly adaptable.
3 Precise positioning
The visual positioning system cooperates with intelligent algorithms, maintains positioning accuracy within ±0.5mm, ensuring operational precision.
4 Efficient operation
The system optimizes the movement proportion of the high-speed section, significantly improving the overall operating efficiency while ensuring accuracy.
5 Wireless integration
The data communication between servers and robots is completed through wireless networks, enabling flexible deployment and simplified maintenance.
In JD Cloud Warehouse project, this solution successfully achieved efficient scheduling and fully automatic access of multi-category boxes, fully verifying its stability and practical value in large-scale warehousing scenarios.
With efficient task analysis, accurate visual positioning and flexible robot collaboration, this solution is also suitable for industries with stringent demands on material turnover efficiency, operation accuracy and warehouse space utilization, such as shoes and clothing, 3C electronics, auto parts, new energy, medical.etc, it empowers clients to achieve unmanned, intelligent and information-based warehouse operations, significantly reduce labor costs, improve operational efficiency, and accelerate the construction of digital logistics system for enterprises.