The core implementation framework of the unmanned automation design scheme for the experimental consumables library has been sorted out and can be directly used for project implementation
1. Overall system architecture design
This scheme is based on the closed-loop logic of "perception decision execution feedback" and is divided into four core levels:
1. Perception layer: Deploy RFID readers, high-definition visual cameras, weight sensors, temperature and humidity transmitters to achieve full lifecycle data collection of consumables, covering the entire process of warehousing, storage, and outbound
2. Data layer: build a edge computing node+cloud management platform, complete real-time data processing locally, and realize consumable inventory visualization, early warning management, and report generation on the cloud
3. Decision making layer: Based on the WMS warehouse management system and AI algorithm model, automatically generate replenishment plans, allocate storage locations, and schedule execution equipment
4. Execution layer: includes four hardware devices: AGV handling robot, robotic arm picking and placing device, automatic gate, and intelligent shelf, to complete the automatic transfer and storage of consumables
2. Automated implementation of core homework processes
1. Storage process: After the supplier delivers the goods, the RFID channel door automatically identifies the batch, specification, and quantity of consumables, synchronously uploads them to the system, and the robotic arm automatically places the consumables in the preset storage location on the intelligent shelf without manual intervention throughout the process
2. Storage link: The intelligent shelf is equipped with temperature and humidity sensors to monitor the storage environment in real time. The system automatically starts the constant temperature and humidity equipment, and dynamically adjusts the storage location according to the turnover rate of consumables. High frequency consumables are placed near the pickup port
3. Outbound process: The laboratory submits a material requisition request through the system, which automatically matches inventory and generates pickup tasks. The AGV transports the corresponding shelves to the pickup area, and the robotic arm accurately retrieves consumables and sends them to the handover window. After scanning the code for confirmation, the outbound process is completed
4. Inventory process: Every month, RFID inventory vehicles are used to automatically traverse the entire inventory. Within one hour, the inventory of consumables in the entire inventory is completed, and an inventory discrepancy report is automatically generated without the need for manual counting
3. Key hardware parameter configuration (2024 industry mainstream standard)
|Equipment type | Core parameters|
|------------------|--------------------------------------------------------------------------|
|Intelligent shelf | Load bearing 50kg/layer, maximum storage height of 8 meters, supports customized warehouse size, compatible with the vast majority of laboratory consumables specifications|
|Collaborative robotic arm | Load 5-10kg, repeat positioning accuracy ± 0.02mm, supports visual recognition to grab irregular consumables|
|Hidden AGV | Maximum load of 500kg, endurance of 8 hours, navigation accuracy of ± 10mm, supports automatic charging|
|RFID Reading and Writing System | Reading and Writing Distance 0-10 meters, Supports Simultaneous Recognition of 500+Tags, Compatible with UHF Ultra High Frequency Electronic Tags|
|Environmental monitoring equipment | Temperature and humidity monitoring accuracy ± 0.5 ℃/± 3% RH, supporting linkage with dehumidifiers and air conditioning equipment|
4. Security and operation guarantee design
1. Safety protection: Install infrared anti-collision sensors and emergency stop buttons in the entire area, set up physical isolation fences in the robotic arm operation area, automatically stop the machine in case of abnormal situations, and push alarm information to the administrator's mobile phone
2. Operation and maintenance management: The system has a built-in device health monitoring module that collects real-time data on motor and sensor operation, predicts fault risks in advance, and automatically generates maintenance work orders
3. Emergency plan: Reserve a manual operation channel, which can be manually switched to semi-automatic mode to complete the operation in case of power failure or system failure
5. Implementation cycle and cost reference for implementation
1. Implementation cycle: About 2-3 months for small consumables warehouses (within 100 square meters), and about 3-6 months for medium-sized warehouses (100-500 square meters)
2. Cost range: The cost of a single solution is about 300000 to 1.5 million yuan, which varies depending on the storage scale and customized requirements
3. Return cycle: Calculated based on an annual reduction of 80% in manual inventory and material requisition costs, the entire investment can generally be recovered within 2-3 years
