Tangyuan Electronic RFID Large Factory Warehouse Forklift Positioning Management System
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1. System significance
With the continuous development and growth of enterprises, the types of materials in warehouses are constantly increasing, and the importance of forklifts in the warehouse is increasing, and forklifts enter and exit the warehouse more and more frequently. In this way, the rational use and overall planning of forklifts are very important. It’s important. At present, the complexity and diversity of warehouse management have made the traditional operation mode of relying on manual and paper inventory records completely incapable of such a huge task. In order to solve the current passive situation of relying on manual dispatch of forklifts, such as low efficiency, insufficient coordination and rational deployment, and insufficient dispatch speed, our company proposes a set of “Warehouse forklift positioning and dispatching management system based on RFID technology” program, relying on advanced technology, Free up the labor force, improve the work efficiency of workers, increase the profit of the enterprise, and enhance the image of the enterprise.
2. System architecture and program description
RFIDThe large-scale factory warehouse forklift positioning and dispatching management system is based on Shanghai Tangyuan Electronic Technology Co., Ltd. according to the current needs of many large-scale factory forklift positioning management and overall scheduling. It uses the most advanced radio frequency identification technology, sensing technology, and monitoring technology in the world today. A security system developed based on, communication technology, and RTLS real-time positioning technology. The system has the characteristics of real-time positioning of the forklift’s position and working status, overall scheduling of forklift work, and checking the activity trajectory of a certain forklift in a specified time period at any time to judge the forklift’s work efficiency and reasonable dispatching conditions.
The company designed the system, following the following principles:
1) Adaptability: To meet and meet the requirements of existing business management, network organization and service quality, we consider the status quo of the enterprise and the status quo of modern logistics management.
2) Flexibility: The system flexibly adjusts the business process and organizational structure according to the development of the enterprise.
3) High reliability and stability: As the RFID management system supported by enterprise warehouse operation and management, the stability, reliability and accuracy of this system are very important. The use of RFID technology and computer network technology is to improve dispatch management capabilities. The selection, configuration, installation, and computer network deployment of RFID equipment can quickly and stably collect and transmit on-site information to the system management center for analysis and dispatch management.
4) Advancement: adopt the most advanced international RFID technology, sensor technology, computer network technology, communication technology, RTLS real-time positioning technology.
5) Openness: Adopt a unified platform, a unified RFID data interface, a unified data dictionary and data structure mode.
6) Maintainability: The system’s standard interface design and modular design make maintenance simple and convenient.
7) Ease of operation: a unified and friendly interface and a complete operation manual make the operation easy to use.
2.1 System architecture
Figure 1 System network architecture
2.2 Program description
We will install a semi-active RFID low-frequency activation electronic tag (model: TY-T602A or TY-T603A) developed and produced by Tangyuan Company on each forklift that needs positioning monitoring. The tag has a unique code. , Each tag is initially bound to the forklift. The tag usually sleeps and does not send a signal to the outside world. Only when it is within the trigger signal range and is awakened by the low-frequency activation locator, will it send a signal to the outside world; secondly, we are in the warehouse entrance and exit and main A low-frequency activation locator (model: TY-A201A) is installed in the aisle to wake up the tag and locate the location of the tag. The distance to wake up the tag is 0.5-8 meters; at the same time, install some active RFID long-distance reading in different places of the warehouse Writer (Model: TY-R301A), used to collect the information sent out after the low-frequency activation electronic tag is activated (including the ID number of the electronic tag itself, the address code of the low-frequency activation antenna, the signal strength RSSI value and the tag battery power status light information ). After the reader/writer collects the data, it uploads the information to the computer management center through various transmission methods. The management center has a set of software systems that we specialize in warehouse forklift positioning and scheduling management, which will analyze and process various data. Storage, judgment, etc., so as to complete the entire warehouse forklift positioning scheduling management system functions.
Figure 2 Schematic diagram of positioning
2.3 System function introduction
1) Monitoring of forklift entering and exiting warehouse:
Install a set of low-frequency activator and long-distance reader at each entrance of the warehouse. The activator has 2 antennas, No. 1 and No. 2, which are placed inside and outside the door, so that they can be monitored anytime and anywhere. The movement of forklifts in and out of the warehouse, including time, location, detailed information about forklifts, etc.
2) Staff attendance management:
At the same time, an electronic label can also be issued to the relevant staff, which can be used to monitor staff attendance and activity trajectory, and control the flow of personnel at any time.
3) Issue tasks:
When the administrator issues a task, he can open the issue task page, enter the corresponding task information, designate the relevant person in charge and the completion time and progress, click Submit the task, and the task is issued.
4) Forklift warehouse positioning:
Through this system, the approximate position of each forklift can be located at any time, which can be accurate to a position of 5 meters around, and the working and dispatching conditions of each forklift can be controlled at any time.
5) Forklift cross-border and sabotage judgment:
Some areas in the warehouse are restricted by forklifts. The system can identify the areas where the forklifts are reasonably running. Normally working forklifts usually move back and forth. If a forklift is found to be stationary in one place for a long time, The system will issue a reminder to determine whether to take a break and slow down work.
6) Historical data query:
Every task is completed, the system has a record. The location of each forklift can be controlled by the system at any time, and relevant data can be retrieved and inquired at any time.
Three, hardware equipment introduction
3.1 Semi-active RFID low-frequency activator
TY-A201A type low frequency exciter
Product Specifications
Performance parameter
Parameter name parameter index remarks
The activation range is equipped with 2 groups of rod antennas, each with a radius of 0 to 5 meters; the maximum identification range can be expanded to 1000m2
The activation speed is up to 400 km/h and can be activated when passing
Activate ability to activate more than 500 labels at the same time
Activation angle omnidirectional
Center frequency 125KHz
Anti-interference ability adopts time division multiple access technology, multiple devices do not interfere with each other
Penetration ability Low-frequency wavelength 2500m can completely pass through the human body and walls
Standard interface TTL, RS485 interface
Power standard DC 12V
Physical parameter
Parameter name parameter index remarks
Packaging characteristics Aluminum alloy shell package
Reliable, waterproof and shockproof, meet the requirements of industrial environment
Size 195*165*77mm (without antenna)
Weight 990g
Installation methods such as ceiling, wall or underground installation
Environmental parameters
Parameter name parameter index remarks
Working temperature -15℃ to 50℃
Storage temperature -20℃ to 60℃
Storage humidity 5% to 95% non-condensing
3.2 Semi-active RFID long-distance reader
TY-R301A type fixed omnidirectional reader
Product Specifications
Performance parameter
Parameter name parameter index remarks
Recognition distance 0～100m radius
Recognition speed 200 km/h
Recognition ability to recognize more than 500 labels at the same time
Recognition angle omnidirectional
Polarization method: vertical polarization or dual polarization
Gain 5dBi, 9dBi, 32 levels adjustable for receiving, 4 levels adjustable for transmitting
Working frequency band 2.4 GHz ~ 2.4835 GHz
Standard working power is milliwatt
The communication mechanism is based on HDLC time division multiple access and synchronous communication mechanism
Anti-interference channel isolation technology, multiple devices do not interfere with each other
Security encryption calculation and security authentication to prevent link detection
Interface standard RS232, RS485, Wiegand26, RJ45, TTL, WiFi, etc. optional
Expansion I/O switch signal input and output 2 channels each (optional)
Power standard DC 12V
Physical parameter
Parameter name parameter index remarks
Packaging characteristics Aluminum alloy shell package
Reliable, waterproof and shockproof, meet the requirements of industrial environment
Size 195*165*77mm (without antenna)
Weight 1050g
Installation method U-shaped, L-shaped special metal installation kit
Environmental parameters
Parameter name parameter index remarks
Working temperature -15℃ to 50℃
Storage temperature -20℃ to 60℃
Storage humidity 5% to 95% non-condensing
3.3 Semi-active RFID desktop card issuer
TY-R401A Desktop Card Issuer
Product Specifications
Performance parameter
Parameter name parameter index remarks
Recognition distance 0～50cm
Recognition ability to recognize single or multiple labels at the same time
The recognition angle is concentrated in the area directly above
Working frequency band 2.4 GHz ~ 2.4835 GHz
Standard working power is milliwatt
The communication mechanism is based on HDLC time division multiple access and synchronous communication mechanism
Anti-interference channel isolation technology, multiple devices do not interfere with each other
Security encryption calculation and security certification, anti-link detection
Interface standard RS232, RS485, RJ45 optional
Power standard DC 12V
Physical parameter
Parameter name parameter index remarks
Packaging characteristics Aluminum alloy shell packaging, front ABS engineering plastics
Reliable lightning protection and impact protection, meeting the requirements of industrial environment
Size 158×99×65 mm
Weight 280g
Environmental parameters
Parameter name parameter index remarks
Working temperature -15℃ to 50℃
Storage temperature -20℃ to 60℃
Storage humidity 5% to 95% non-condensing
3.4 Semi-active RFID electronic tags
TY-T602A dual-frequency card type electronic label
Product Specifications
Performance parameter
Parameter name parameter index remarks
Recognition distance is adjustable from 0 to 80 meters (usually dormant, signal will be sent after being triggered by low-frequency trigger)
Recognition speed 200 km/h
Recognition ability with 200 frames/sec anti-collision performance
Recognition method omnidirectional recognition
Fixed gain 0～3 level can be selected on demand
Working frequency 2.45GHz, 125KHz
Communication rate 250K, 1M, 2M b/s
The communication mechanism is based on HDLC time division multiple access and synchronous communication mechanism
Anti-interference channel isolation technology, multiple devices do not interfere with each other
Security encryption calculation and security authentication to prevent link detection
Read and write function 176B or 1KB storage space (optional)
Anti-dismantling functionAnti-dismantling alarm function (optional)
The average working power is microwatt-level
Battery configuration soft pack lithium manganese battery, capacity 750mAh
Service life is about 5 years, low voltage alarm
When the voltage detection voltage is lower than the preset value, it will wirelessly prompt (optional)
Physical parameter
Parameter name parameter index remarks
Packaging characteristics: ABS+PC material, resistant to high-strength drop and vibration
Reliable, waterproof and shockproof, meet the requirements of industrial environment
Square card shape, OEM customized service can be provided
Size 91×59×6.5 mm
Weight 26g
Installation method double-sided adhesive paste or hanging buckle
Environmental parameters
Parameter name parameter index remarks
Working temperature -15℃ to 50℃
Storage temperature -20℃ to 60℃
Storage humidity 5% to 95% non-condensing
TY-T603A type tri-band electronic label
Product Specifications
Performance parameter
Parameter name parameter index remarks
Recognition distance is adjustable from 0 to 80 meters (usually dormant, signal will be sent after being triggered by low-frequency trigger)
Recognition speed 200 km/h
Recognition ability with 200 frames/sec anti-collision performance
Recognition method omnidirectional recognition
Fixed gain 0～3 level can be selected on demand
Working frequency 2.45GHz, 125KHz, 13.56MHz
Communication rate 250K, 1M, 2M b/s
The communication mechanism is based on HDLC time division multiple access and synchronous communication mechanism
Anti-interference channel isolation technology, multiple devices do not interfere with each other
Security encryption calculation and security authentication to prevent link detection
Read and write function 176B or 1KB storage space (optional)
The average working power is microwatt-level
Battery configuration soft pack lithium manganese battery, capacity 750mAh
Service life is about 5 years, low voltage alarm
When the voltage detection voltage is lower than the preset value, it will wirelessly prompt (optional)
Physical parameter
Parameter name parameter index remarks
Packaging characteristics: ABS+PC material, resistant to high-strength drop and vibration
Reliable, waterproof and shockproof, meet the requirements of industrial environment
Square card shape (hanging buckle ear tags in both horizontal and vertical directions), OEM customized service can be provided
Size 90×60×7.0 mm
Weight 28g
Installation method double-sided adhesive paste or hanging buckle
Environmental parameters
Parameter name parameter index remarks
Working temperature -15℃ to 50℃
Storage temperature -20℃ to 60℃
Storage humidity 5% to 95% non-condensing
4. Project budget
The following budget is designed assuming a 5,000 square meter warehouse with 4 entrances and exits.
Each of our low-frequency activation location can be equipped with 2 antennas, each antenna can cover a circle with a diameter of 8 meters, so that it can be calculated that each activator can cover an area of approximately 100 square meters, 5000 square meters of signal coverage, then It needs 50 low-frequency activation locators, and the distance of each long-distance reader/writer receiving signals in an indoor environment is within a circle area of a 30-meter radius. In this calculation, in order to make the signal full coverage without blind areas, 4 long-distance units are designed Readers; and each access control requires a set of equipment (including a low-frequency activator and a reader), 4 doors, a total of 4 readers and 4 activators; low-frequency activation electronic label design 50 sheets .
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