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The Design of Stereoscopic Warehouse Stacker' Motion
and Control System
Abstract. With the continuous improvement of industrial automation, automated warehouse has been widely used in various industries to improve the production efficiency and Logistics speed to a great extent. As an essential equipment of automated warehouse, stacker' working efficiency and stable performance will affect the usability of the warehouse directly. This essay studies the tunnel type stacking in machine' speed control system of an automated warehouse, and analysis its motion curves. Then we combine it with the stacker's composite material structure to guarantee better motion control accuracy and motion reliability.
Keywords: stereoscopic warehouse, stacker, motion control.
1 Introduction
Modern automated warehouse is a modern warehouse which uses high-dimensional shelf to store materials, and to control management by computers and making access role by automatic stacking trucks. In recent years, stereoscopic warehouses has highly improved related enterprises 'production and logistics speed. Stacker is an important and indispensable equipment in a stereoscopic warehouse, its working efficiency and stable function affects stereoscopic warehouse' efficiency and economic benefits fundamentally. As a whole, stacker's evaluation performance includes：lifting speed, running speed, goods forking speed, and stability and address recognition accuracy. Among all the evaluation performances, the stacker's speed is the essential factor, because it can control can deeply affect the stability, the vibration situation, and address recognition accuracy of stacker's operation. So, making In-depth research in stacker's motion situation and speed control system is extremely important, it can help us to make sackers with high—efficiency, more stable and larger motion range.
2 Motion Control of the Stacker
2.1 Abstract
An stacker's motion control technology mainly reflects in its motion speed control,
Nowadays there are several methods of stacker's motion speed control, as been
showed below：
1） Multi-range speed control mode. This control mode is built in a certain usage foundation. When it's working, we must consider the stacker's actual control need and it also can use sub-file operation mode according to relevant experience. To a large extent, this mode needs coordination exercise control and it also requires dealing with Inverter's performance.
2) Using inverter to complete the closed-loop speed stacker and stacker control displacement's open-loop control, usually, the Stacker's ideal motion curve can be concluded to Standard acceleration and deceleration curves. After one motion's experimental curve being confirmed, it can be stored in a stored and we can use PLC to control the inverter to change the motion curve, thus we achieve the purpose of accurate speed and stop.
3) There are some problems in the turning point in speed and acceleration switch of stacker movement functions. To solve this problem, we can use the fuzzy control technology to make reasonable improvement.
A mechanical processing factory's warehouse is mainly used for mould、the storage of semi-finished products and finished products processing. It has the function of automatic management store items. The deposit product for stacker deposit requirement is taken must be fast, stable and reliable. The control system adopts PLC as the master components; it has a greater flexibility and high reliability. Warehouse stacker uses common stacker machine, the weight is of 0.25-1.5 tons, and its operation speed is from twenty five to one hundred and eighty meters per minute. It mainly composed of the body, the level of operating agencies, vertical hoisting mechanism, telescopic fork loading station and institutions and several other components. The main structure of stacker machine is as shown in figure 1 below:
Fig. 1. Stacker machine's main structure
2.2 The Set of the Velocity of the Stacker
From the main structure of stacker machine ,we can also know, tuckers' major sports includes three basic action, these are：level of movement mechanism、the vertical lifting mechanism's up and down movement、adjustable action in goods fork telescopic machine. So, stackers' final task efficiency, its movement and performance is also decided by these three movements of the basic control degree. When stacking machine is moving, to ensure the movement is smooth and reliable, we must ensure that the stop registration of movement's accuracy and its movements flatness by some certain control strategy. The method of motion speed is to adjust the operating curve, and then stored it in control memory. When PLC is controlling the motion, through changing the curve which is stored in the inverter we can achieve the purpose of accurate speed and stop.
Level speed setting mechanism is settled for four gears, these are crawling, low speed, middle and high speed. When PLC is controlling the motion, it receives the destination address from a controller, then it Compare the current address to the destination address, and calculate the distance from current address distance to destination address. Make a good’s distance as a unit distance. When the distance is larger than six units distance, it use the motion mode of curve a, and use proper acceleration speed when starts and stops, to ensure the precision of the prospective stop. It also use maximum speed to operate in the middle location. Thus it can improve the efficiency. When the distance is less than six units distance yet greater than two units distance, it use the motion mode of curve b. And when the distance is less than two units distance, it use the motion mode of curve c.
Fig. 2. The graph of level mechanism's speed
Similarly, the vertical lifting operation of lifting mechanism sets three different speeds. When the operation is normal, it adopts high speed to improve efficiency. When it approaches the target, it down to low speed in order to raise the stop precision. Vertical lifting mechanism's speed curve is as shown in Fig. 3:
Fig. 3. The graph of Vertical lifting mechanism
The role of the fork telescopic machine goods is through the telescopic movement to put corresponding goods to goods box. The speed of expansion movement can not be too fast, so it can reduce the impact of the equipment action. In this system, adjustable speed of goods fork is been settled to two gears, normal expansion speed is 10 m/min speed, and when is close to the goods the speed is 4m/min.
2.3 Positioning Control of Stacker
Besides controlling the motion speed, stackers' positioning control directly affects the stop precision. So, the position control of stacker system is an important indicator of stacker motion control system.
Stackers positioning control includes the above three positioning accuracy of motion organizations, among them, the level address system is the foundation of stackers motion position. Its function deeply affects the stackers' working efficiency and mechanical properties. In the motion aspect, the stackers' access to goods is very frequent, so it requires high efficiency and positioning correct in motion. From stacker mechanical structure, the stacker which used this system can move heavier goods. So it requires when a stacker is in acceleration and deceleration, column of the deformation must be in the allowable range.
As for stackers' automatic control system, automatic stop bit is the most fundamental question. Now the widely used reorganization address location technology, it can be divided into photoelectric sensor address technology, rotary encoder address technology and laser ranging address technology in general. This system uses the photoelectric sensor obtain address, uses the recognition of address and machine of address to compose the stacker's automatic device of address. It also uses relative obtain address, that means uses photoelectric switch when passing the corresponding goods position, through the photoelectric sensor to produce electrical impulses, according to different moving direction, to address code add one or minus one operation, use PLC count to record the current address,. In the car body, we put two position— different photoelectric switches. When PLC captures the first switch's moves, it makes car body to slow down; when it captures the second switch moves, it makes the car body stop. The motion control method vertical movement mechanism, goods fork telescopic machine and level control method is similar. The location of the device level control is as shown in Fig.4:
Fig. 4. Level control positioning scheme
As the scheme shows, when it making horizon movement, PLC figures out the distance from current position to the target position. In place of the other position before the orientation patch is used to count, after getting to the destination address, the first action photoelectric switches, car body slows down, through reasonable control of haste and slow acceleration, to ensure when the latter photoelectric switch moves, then the car body just stop. Thus, it can guarantee the car body operates in reasonable speed and acceleration. Slow speed operation time is short. This improves the operation condition of the motor to greater extent. It also has much advantage in reliability and stability of the system.
3 Conclusion
These above design process ensure the stacker machine movement's performance in movement of speed and positioning accuracy. After the motion control method being used in the actual operation of the factory warehouse, it get a good effect. But as for the influence on the performance of the movement in actual movement speed and acceleration, we still need making deeper analysis to a large extent.
立體倉庫碼垛機(jī)的設(shè)計及控制系統(tǒng)
摘要：隨著工業(yè)化的不斷提高，自動化立體倉庫已被廣泛應(yīng)用于各個行業(yè)，在很大程度上提高了生產(chǎn)效率和物流速度。作為必不可少的設(shè)備的自動化立體倉庫，碼垛機(jī)的工作效率和穩(wěn)定的性能將直接影響倉庫的可用性。本文研究了巷道式碼垛機(jī)的速度控制系統(tǒng)的自動化立體倉庫，分析其運(yùn)動曲線。然后，我們把它與堆垛機(jī)的復(fù)合材料結(jié)構(gòu)，以保證更好的運(yùn)動控制精度和運(yùn)動的可靠性。
1關(guān)鍵詞：立體倉庫，堆垛機(jī)，運(yùn)動控制。
現(xiàn)代自動化立體倉庫是一個現(xiàn)代化的倉庫，它采用立體貨架存儲材料，并控制由計算機(jī)和訪問管理的作用，自動碼垛。近年來，立體倉庫，高度提高了相關(guān)企業(yè)的生產(chǎn)和物流速度。在立體倉庫，碼垛機(jī)是不可缺少的重要設(shè)備，它的工作效率和穩(wěn)定的功能從根本上影響立體倉庫的工作效率和經(jīng)濟(jì)效益。作為一個整體，堆垛機(jī)性能評估包括：提升速度，運(yùn)行速度快，商品分叉速度，穩(wěn)定和地址的識別精度。在所有的評價性能，碼垛機(jī)的速度是重要的因素，因為它可以控制可以深刻地影響穩(wěn)定性，振動的情況下，堆疊器的操作和地址識別精度。所以，在碼垛機(jī)的運(yùn)動情況和速度控制系統(tǒng)的深入研究是非常重要的，它可以幫助我們使碼垛機(jī)具有高效率，更穩(wěn)定和更大的運(yùn)動范圍。
2碼垛機(jī)的運(yùn)動控制
2.1摘要
堆垛機(jī)的運(yùn)動控制技術(shù)主要體現(xiàn)在它的運(yùn)動速度控制，現(xiàn)在有幾種方法堆垛機(jī)運(yùn)動速度控制，顯示如下：
1） 多范圍的速度控制模式。這種控制方式是建立在一定的使用基礎(chǔ)。它的工作時，我們必須考慮堆垛機(jī)的實際控制需要，并根據(jù)相關(guān)的經(jīng)驗，也可以使用子文件操作模式。在很大程度上，這種模式需要協(xié)調(diào)運(yùn)動的控制，同時也需要處理與逆變器的性能。
2） 通常情況下，使用變頻器來完成閉環(huán)高速碼垛機(jī)，碼垛機(jī)控制位移的開環(huán)控制，碼垛機(jī)的理想運(yùn)動曲線可以得出結(jié)論為標(biāo)準(zhǔn)的加速和減速曲線。一個運(yùn)動的實驗曲線被證實后，它可以存儲在存儲，我們可以用PLC控制變頻器來改變運(yùn)動曲線，從而實現(xiàn)精確的速度和停止的目的。
3） 在堆垛機(jī)移動功能的開關(guān)速度和加速度的轉(zhuǎn)折點也存在一些問題。為了解決這個問題，我們可以采用模糊控制技術(shù)，使合理的改善。
機(jī)械化立體倉庫主要用于模具，儲存的半成品和成品加工。它具自動管理存儲項目的功能，立體化倉庫儲存產(chǎn)品要求必須具有快速、穩(wěn)定、可靠性?？刂葡到y(tǒng)采用PLC作為主要部件，它有更大的柔性和高的可靠性。倉庫碼垛機(jī)使用常見的碼垛機(jī)，重量為0.25-1.5噸，其運(yùn)算速度是每分鐘25180米。它構(gòu)架主要部分，水平的經(jīng)營機(jī)構(gòu)，垂直起升機(jī)構(gòu)，伸縮臂叉裝車站和機(jī)構(gòu)等幾個部分組成。堆垛機(jī)的主要結(jié)構(gòu)的示出在圖1所示：
圖1 碼垛機(jī)主要構(gòu)架
2.2碼垛機(jī)的速度集
從碼垛機(jī)的主要構(gòu)架我們可以知道，碼垛機(jī)的主要運(yùn)動包括三個基本動作，它們是：水平，垂直升降機(jī)構(gòu)運(yùn)行機(jī)制的向上和向下運(yùn)動，可調(diào)貨叉伸縮機(jī)的行動。因此，碼垛機(jī)的最終任務(wù)的效率，它的運(yùn)動和性能還決定于這三個運(yùn)動的基本控制程度。當(dāng)碼垛機(jī)運(yùn)動時，我們必須確保運(yùn)動的平穩(wěn)于可靠。我們也必須通過一些策略來控制它運(yùn)動的精度于平整度。這種方法是調(diào)整過的速度曲線存到儲存器中。當(dāng)PLC控制的運(yùn)動，通過改變儲存在逆變器中的曲線來達(dá)到精確控制速度和聽的目的。
速度等級設(shè)置四檔，爬行，低速，中高速。當(dāng)PLC控制的運(yùn)動，它從控制器接收目的地址，然后，它比較當(dāng)前地址到目的地址，并計算距離從當(dāng)前地址到目的地址的距離。使貨物的地址作為一個單位地址，當(dāng)該距離大于六個單位的距離時，它使用的曲線a的運(yùn)動模式，在啟動和停止時使用適當(dāng)?shù)募铀俣?，以確保準(zhǔn)停止精度。
它還使用最大速度在中間的位置進(jìn)行操作。因此，可以提高工作效率。當(dāng)該距離小于6個單位的距離大于兩個單元的距離，它使用曲線b的運(yùn)動模式。當(dāng)距離小于兩個單位的距離，使用曲線c的運(yùn)動模式。
圖2 水平運(yùn)動速度
同樣地，在垂直升降的升降機(jī)構(gòu)的操作設(shè)置三種不同的速度。當(dāng)操作是正常的，它采用高速，以提高效率。當(dāng)它接近目標(biāo)時，它下降到低轉(zhuǎn)速，以提高的停止精度。垂直升降機(jī)構(gòu)的速度曲線圖3所示：
圖3 垂直升降圖
叉伸縮機(jī)的作用是通過叉伸縮運(yùn)動把貨物送到正確的位置。擴(kuò)展運(yùn)動的速度不能太快，它可以降低設(shè)備的動作的影響。在這個系統(tǒng)中，速度可調(diào)的貨叉被算到兩個齒輪，正常擴(kuò)張速度是10米/分鐘的速度，并且當(dāng)接近速度為4m/min的貨物。
2.3定位控制碼垛機(jī)
除了控制運(yùn)動速度，碼垛機(jī)的定位控制直接影響到停止精度。因此，堆垛機(jī)運(yùn)動控制系統(tǒng)，堆垛機(jī)的位置控制系統(tǒng)的一個重要指標(biāo)。
碼垛機(jī)定位控制包括上述三個定位精度的運(yùn)動組織，其中，地址系統(tǒng)的基礎(chǔ)碼垛機(jī)運(yùn)動位置。其功能深深影響的堆垛機(jī)的工作效率和機(jī)械性能。在運(yùn)動方面，貨物堆垛機(jī)的訪問是很頻繁的，因此需要高效率和定位正確的運(yùn)動。由于碼垛機(jī)的機(jī)械結(jié)構(gòu)使得它可以搬用較重的產(chǎn)品。因此，碼垛機(jī)是在加速和減速時，柱的變形必須是在允許范圍內(nèi)。
堆垛機(jī)的自動控制系統(tǒng)，自動停機(jī)位是最根本的問題?，F(xiàn)在廣泛使用的重組的地址位置技術(shù)，它一般可分為光電傳感器址技術(shù)，旋轉(zhuǎn)編碼器地址技術(shù)和激光測距址技術(shù)。此系統(tǒng)使用的光電傳感器獲取地址，使用的地址組成的堆疊器的自動裝置的地址的地址和機(jī)器的識別。它也使用相對獲取地址，這意味著使用光電開關(guān)，通過相應(yīng)的貨物的位置時，通過光電傳感器，以產(chǎn)生電脈沖，根據(jù)不同的移動方向，以解決代碼加1或減一操作，使用PLC計數(shù)記錄當(dāng)前地址。在車身上，我們把兩個位置不同的光電開關(guān)。當(dāng)PLC捕捉到的第一個開關(guān)的動作，它使車身放慢，它抓住了第二次的開關(guān)動作時，它使車身停止。垂直運(yùn)動機(jī)構(gòu)的運(yùn)動控制方法，貨叉伸縮機(jī)和電平控制的方法是相似的。電平控制的位置如圖3所示：
圖3 水平位置控制方案
按計劃顯示，當(dāng)它使地平線運(yùn)動，PLC的距離計算出從當(dāng)前位置到目標(biāo)位置。在其他位置的方向修補(bǔ)程式之前，后到目的地址是用來計數(shù)的，第一個動作光電開關(guān)，車身減慢，通過合理控制加速和減速加速，以確保后者光電開關(guān)動作，然后在車身上就停止了。因此，它可以保證車體工作在合理的速度和加速度。速度慢的操作時間很短。這更大程度上提高電機(jī)的運(yùn)轉(zhuǎn)狀態(tài)。它有很大的優(yōu)勢在于該系統(tǒng)的可靠性和穩(wěn)定性。
3結(jié)論
這些上述的設(shè)計過程中的運(yùn)動速度和定位精度確保堆疊器的運(yùn)動性能。運(yùn)動控制方法運(yùn)用在實際操作中的工廠倉庫后，取得了良好的效果。但在實際的運(yùn)動速度和加速度的運(yùn)動性能的影響，我們還需要在很大程度上更深入的分析。
The flexible manufacturing system
The flexible manufacturing system(FMS) train points to have the high manufacturing system of the automation degree.The FMS speak about usually means in the lot size, batch size machining of metals currently with the forerunner's automation and Gao level of flexible is the manufacturing system of target.Along with society to product diversification, the low manufacturing cost and short manufacturing period's etc.'s need be gradually urgent, the FMS deveolps very and quickly, and because of micro-electronics technique, calculator technique, correspondence technique, machinery and the development of controlgear, also urge flexible manufacturing technique day attain mature, in 80's after, the manufacturing industry automation gets into for a brand-new ages, namely according to calculator of integrated manufacturing(CIMS) ages, the FMS has become the national machinery manufacturing of each industrialization to automate of develop and deveolp point.
A, scale
Press the scale all of the FMSs can be is divided into as follows 4 types:
1.Flexible Manufacturing Cellular(FMC)
The FMC publish and use to invite ratio FMS late in the manufacturing for 6~8 years, it is processed a centre, industrial robot by 1~2 and counts to control engine bed and material carrying to save to store equipments composing and have an adaptation to process have another species product of vivid.The FMC can be regarded as a FMS with minimum scale, is a FMS to cheap turn and small scaled turn direction development and a kind of outcome, its characteristics is to carry out single machine flexible turn and automate, have already get into up to the present universal application step.
2.Flexible Manufacturing System(FMS)
Usually include 4 or more full-automatic numbers to control engine bed(process centre and truning centre etc.), from concentrate the handling system of control system and material to connect, can under the sistuation that not shut down realization have another species, in process of small lot size, batch size and manage.
3.Flexible Manufacturing Line(FML)
It is be placed in the quantisty not- flexible and automatic line of single or little species large quantity with medium small lot size, batch size have another of species FMS of manufacturing line.It processes an equipments and can be an in general use earth, ground to process a centre, CNC engine bed;May also adopt definite purpose engine bed or NC definite purpose engine bed, have low request at the FMS to the system flexible earth, ground of the material handling, but the rate of manufacturing be higher.It with the long-lost type produce medium flexible manufacturing system with connect the control system(DCS) of the dispersion type within manufacturing line is representative, its characteristics is to carry out manufacturing line flexible turn and automate, its technique already the day attain mature, have already got into application to turn step up to the present.
4.Flexible Manufacturing Factory(FMF)
The FMF connects several FMSs, go together with to automate stereoscopic storehouse, use the progress contact of the calculator system, adoption from order, design, process, assemble, examine, deliver to hair goods of complete FMS.It included CAD/CAM, and make calculator integrated to make system(CIMS) devotion physically, realization manufacturing the system be flexible to turn and automate and then carry out whole plant the manufacturing control, product of the scope to process and the material store completely turn of the luck progress.The FMF is the tallest level that the automation produce and the reflection is most born the top of the boundary the forerunner's automation application a technique.It is manufacturing, product development and management the automation of management connect into one whole, with information stream control substance stream of intelligence manufacturing system(IMS) is representative, its characteristics is to carry out works flexible turn and automate.
Two, key technique
1.Computer Aided Design, CAD
The CAD technique development will lead into the expert system in the future, make it have intelligence to turn, can treat various complicated question.At present design a latest of the technique breakthrough is that the light is quick stereoscopic forming technique, that the new technique be directly to make use of CAD data and pass a computer control of laser scanning system, be divided into some lamellas:3Dnumerical pattern a two-dimensional flake form sketch, and press the two-dimensional flake form sketch to carry on an optics scanning to the quick resin liquid surface of the light in the bath, is scan of the liquid surface then becomes curing plastics, thus circularly operate, pursue lamella to scan to take shape, and of oneself glue the each flake form curing plastics that the delamination take shape to match together and only need certain data, then can make a prototype of precision in few hours.It contributes to quickly developping new product and developping the speed of new structure.
2.Fuzzy control technique
The actual application of misty mathematics is a fuzzy control machine.The high performance fuzzy control apparatus which develops recently has from the study function, can in the process of control in continuously obtain a new information and of oneself make an adjustment to the control quantisty, make system function greatly in order to improve, among them particularly with according to artificial neural net, artificial neural network, ANN of self-educated method cause people tremendous concern more.
3.Artificial intelligence, expert system and intelligence transducer technique
Up to the present, the artificial intelligence adopt mostly points according to the expert system of rule in the FMS.The expert system makes use of expert knowledge and reasons logically rule progress a reasoning and solve each kind of question.(like explanation, predict, diagnose, check to seek a fault, failure, design, plan, keep watch on, repair, command and control etc.)Because expert system can simplely the theory of various fact and experience certificate super - with pass the knowledge of experience acquisition to combine together, as a result the expert system intensified for the FMS various aspect operate gentle.Prospect a future, with knowledge intensively is characteristic, with the knowledge treat for the artificial intelligence(include expert system) technique of way necessarily will have in the FMS(particularly intelligence type) decisive action.The artificial intelligence is in the future FMS lieutenant general exertive gradually important action.Used for various technique in the FMS currently, anticipate to there is the artificial intelligence of the is still of development prospect most .Anticipate till the beginning of 21 centuries, the artificial intelligence is in the FMS of applied scale will compare currently greatly400%.The intelligence manufacturing technique(IMT) aim is in the process of integrating the artificial intelligence into the manufacturing each link, ask for help of intelligence of imitate the expert movable, replace or extend a manufacturing environment parts of mental works of the middleman.In the process of make, the system can automatically monitor it to circulate condition, while be subjected to the external world or inner excitation energy the automatic regulation