RFID intelligent management design solution for warehouse logistics

I. Project Overview

1. Project Background

In logistics management, warehouse management is a crucial link. Traditional warehouse management has many problems, such as chaotic in-and-out operations, delayed inventory reporting, unclear product attributes, chaotic stacking, inaccurate inventory, etc. These problems need to be thoroughly transformed through information management-based technologies.

Warehouse management based on RFID technology can change the traditional warehouse management methods and processes. By attaching RFID tags to goods, efficient and accurate management of the core business processes of warehouse management (outbound, inbound, inventory, inventory control) can be achieved. RFID technology has the advantages of long identification distance, fast speed, not easy to damage, and large capacity. It can simplify cumbersome work processes, effectively improve the efficiency and transparency of warehouse management, and make the business operations of enterprises more lean and efficient.

Some large retailers, such as Walmart, have begun to deploy RFID warehouse management systems in item warehouses and distribution centers. According to some research institutions, Walmart's RFID system generates about 7 megabytes of data every day. Therefore, for RFID warehouse management systems, how to Store and retrieve massive RFID data is also an urgent problem to be solved.

2. Project Objectives

As the core business system of an enterprise, the warehouse management system (WMS) uses computer software to simulate the system process of warehouse management, aiming to simplify practicality and improve the quality and efficiency of warehouse management.

The system needs to scientifically manage the centrally placed materials, realize efficient and accurate in-and-out warehouse operations, and submit the updated information of goods to the server database in a timely manner. The upper management system needs to ensure that the quantity of goods does not change during storage, maintain the corresponding in-and-out warehouse records and regular inventory information.

In terms of goods storage, the system needs to maximize the use of space, maximize and most effectively utilize labor and equipment, and realize convenient goods storage and rapid positioning. In addition, the management system needs to implement an efficient and accurate in-and-out verification and audit mechanism to complete more in-and-out operations without error within a limited working time, thereby saving human resource consumption and avoiding errors caused by human factors.

2. Project Requirements

1. Requirements for warehouse management system

Traditional warehouse management generally relies on a non-automated, paper-based system combined with manual memory to achieve inventory management. This method is not only time-consuming and labor-intensive, but also prone to errors, making the cargo storage process inefficient and causing immeasurable losses to the company.

Main functions of the system

2. Requirements for the warehousing module

In the finished product packaging workshop, workers attach RFID electronic tags to products and pack them in batches. If pallets are required, they can also attach pallet labels after palletizing. The general labeling methods are: (1) labeling of individual products; (2) labeling of multiple products together and labeling of the outer packaging; (3) labeling of pallets, and associating them with the label of a single product or the label of the outer packaging.

When entering the warehouse, the RFID Reader and RFID Antenna channel automatically obtains the number of incoming goods and records it in the system. The pallet cargo information is written into the pallet label through the RFID reader at the inlet and associated with the order data. The system calculates the warehouse location based on the inventory management information, or the warehouse location is manually specified.

2.1 Warehousing module business

Fixed RFID readers are deployed at the warehouse entrance, and radio frequency planning is performed according to the on-site environment. For example, four antennas can be installed on the top, bottom, left, and right sides to ensure that the RFID electronic tags are not missed.

When the RFID electronic tag enters the range of the reader, it will automatically activate and communicate with the RFID reader. After the collection is completed, the system will compare it with the order to check the accuracy of the quantity and model of the goods. If there is an error, it will be manually processed. After the goods are delivered to the designated location, they will be placed according to the rules. The main advantage of RFID technology is non-contact long-distance identification, which can be read in batches to improve efficiency and accuracy.

2.2 Requirements for the implementation of the warehousing module

The warehouse management system can display the location, quantity and specification model of each item to realize the visualization of the storage status. After completing the warehousing operation, the system automatically generates a data sheet for the incoming products, recording the name, type, production date, warehousing time, warehousing batch, quality status, warehousing quantity, warehousing handler and warehouse code of the incoming products for query.

3. Requirements for the outbound module

The shipper of the department generates an outbound order according to the sales requirements, and inquires the warehouse about the storage location and inventory status of the outbound goods according to the outbound priority. The consignee takes the delivery order to the warehouse administrator, and after checking the information, he arranges the loading and unloading personnel to perform the delivery operation. The loading and unloading personnel pass through the exit gate, and the RFID reader reads the RFID tag on the pallet to obtain the delivery information, and verifies whether the product batch number and storage location in the delivery order are correct. After the delivery is completed, the warehouse terminal prompts the delivery details for the administrator to confirm and automatically updates the database.

3.1 Delivery module business

According to the delivery plan, the delivery goods are sorted and processed, and the delivery management is carried out. For a large number of goods, a fixed RFID reader can be used to communicate with the RFID tag to collect the RFID electronic tag information of the delivery goods. For a small amount of goods, an RFID handheld terminal can be used to collect the information of the RFID electronic tag. When an error occurs, an alarm will be issued. The staff should handle it in time and send the data to the management center to update the database.

3.2 Requirements for the outbound module

The loading and unloading personnel go to the designated cargo location to pick up the goods according to the shipping instructions, and confirm the accuracy of the goods again, and then send the goods to the outbound conveyor belt. The RFID reader of the outbound conveyor belt reads the cargo label information for verification to ensure that it is accurate before shipping.

4. Inventory module requirements

Warehouse management personnel use RFID handheld terminals to walk by each shelf or pallet, read the quantity and type of goods, and accumulate them. After the inventory is completed, an inventory report is generated, which is compared with the actual inventory quantity in the warehouse, and the data information in the system is corrected to ensure that the goods are consistent with the accounts.

4.1 Inventory module business

According to the warehouse management requirements, regular or irregular inventory is carried out, and the RFID handheld terminal is used to scan the goods inventory. The inventory information is transmitted to the background database through the wireless network, and compared with the information in the database. The difference information is generated for the inventory staff to check. After the inventory is completed, it is checked with the background database information to ensure accuracy.

III. Technical Solution

1. Hardware Platform

(1) UHF fixed RFID reader: used for warehouse access management and inventory positioning of materials.

(2) RFID handheld terminal: used for inventory management of warehouse materials.

(3) RFID electronic tag: as a unique mark to identify warehouse goods.

(4) Application PC: used to run the warehouse management system.

(5) WEB server: used to provide remote access to the warehouse management system.

(6) Database server: used to store and manage data of the warehouse management system.

For a single warehouse, warehouse access management can be managed by fixed readers, and inventory positioning of warehouse materials can be managed by handheld readers.

1.1 Hardware Layout

In the label placement scheme, special attention should be paid to the label placement position to ensure the best reading and writing effect. The label placement method is determined according to the goods of different media, which are mainly divided into anti-metal labels and non-anti-metal labels. Anti-metal labels are suitable for affixing to the surface of metal goods, and non-anti-metal labels are suitable for affixing to non-metal goods. Goods such as wooden boxes, canvas bags, plastic bags, cartons, etc. can all be identified by non-metal labels.

In warehouse management, pallet-level management is usually adopted, that is, the goods on a pallet are operated as a unit. The size of a standard pallet is 3000px*2500px*375px. Therefore, when affixing labels, one label is usually affixed to a pallet for identification, and the affixing position is determined according to the specific pallet goods stacking method. Under normal circumstances, the stacking height of goods on a pallet does not exceed 2000px, that is, the maximum height of the pallet and goods stacked together does not exceed 1m.

2. Software platform

(1) Operating system: It is recommended to use an operating system above Windows 2000.

(2) Data communication: 10/100 Ethernet and RS232 serial port are used for data communication.

(3) Database: The database management system of SQL Server 2000 is used.

(4) Development language: The main interface is developed using C++ or Java.

The system includes warehouse inbound management software, warehouse outbound management software and inventory management software.