Integrated Optimization Framework for AS/RS: Coupling Storage Allocation, Collaborative Scheduling, and Path Planning via Hybrid Meta-Heuristics

Automated Storage and Retrieval Systems (AS/RSs) are pivotal hubs in modern intelligent logistics, yet their operational efficiency is often constrained by the complex coupling of storage allocation, equipment scheduling, and path planning. This study proposes a systematic optimization framework to address these three critical control challenges. First, a multi-objective mathematical model for storage location allocation is established, considering efficiency, stability, and correlation. To solve this high-dimensional discrete problem, a Tabu Variable Neighborhood Search (TVNS) algorithm is proposed, integrating short-term memory mechanisms with multi-structure exploration to prevent premature convergence. Second, regarding stacker crane and forklift collaborative scheduling, a Pheromone-guided Artificial Hummingbird Algorithm (PT-AHA) is introduced. By incorporating pheromone feedback into foraging behavior, the algorithm significantly enhances global search capability to minimize total task completion time. Third, stacker crane path planning is modeled as a constrained Traveling Salesman Problem (TSP) and solved using a hybrid Simulated Annealing-Whale Optimization Algorithm (SA-WOA). Quantitative simulation results demonstrate that the TVNS algorithm improves storage allocation fitness by 1.1% over standard Genetic Algorithms, while the PT-AHA reduces task completion time (Makespan) by 21.9% for small-scale batches and consistently outperforms ACO by up to 3.6% in large-scale operations. Validation through an Intelligent Warehouse Management System (WMS) confirms that the integrated framework maintains high industrial resilience by triggering fault alarms and initiating recovery within 3.2 s during simulated equipment failures, providing a robust solution for enterprise-level deployments.