Focus on AGV industry for 18 years
Focus on AGV industry for 18 years
The PACK production line of a leading company in the new energy lithium battery industry is facing increasingly complex production demands, requiring a highly reliable and precise smart logistics solution to enhance overall efficiency. This production line involves multiple processes, with diverse and frequent material handling needs between different workstations. The design of the smart logistics system must fully consider the specific requirements of each workstation to ensure timely delivery and accurate placement of materials. Additionally, real-time monitoring and adjustments during the production process are necessary to ensure coordinated operations across all stages, avoiding production bottlenecks caused by handling delays.
To achieve efficient and smooth operation of the production line, the AGV control system will be interface-connected with the workshop's MES system and the PLCs of key workstations. This integration will ensure that the AGV/AMR can instantly acquire status information from the production line, thereby optimizing dispatch strategies and rationally arranging handling tasks. Through seamless integration with the workshop systems, the AGV/AMR can not only enhance production efficiency but also improve resource utilization, reducing manual intervention and operational errors. The successful implementation of this project will provide the customer with robust technical support in the competitive market, further solidifying their leading position in the electric vehicle sector.
The PACK assembly line includes both manual and automated workstations, requiring AGV/AMR to precisely control stops, releases, and circulation operations between different stations. Each workstation has different operational requirements and processes, necessitating that AGV/AMR possesses high-precision positioning and motion control capabilities to ensure the smooth completion of handling tasks. Such precision demands pose greater challenges to the stability and reliability of AGV/AMR.
AGV/AMR must interact with the workshop PLC system via a wireless network for real-time data exchange, ensuring the safety and stability of the material handling process. The complexity of the production environment may lead to signal interference and network delays; therefore, AGV/AMR must have strong anti-interference capabilities and real-time data processing abilities to promptly respond to PLC commands under changing production conditions and achieve efficient collaboration.
AGV/AMR must be compatible with various sizes of material carts and adapt to the full range of products in the PHEV series. Differences in size, weight, and shape among different products require AGV/AMR to have flexible adaptability and the ability to automatically recognize and adjust handling strategies. This necessitates that the AGV system be equipped with modular design and intelligent control to effectively cope with changes and challenges on the production line.
CASUN Intelligent Robotics has designed and implemented a highly customized smart logistics comprehensive solution to address the complex needs of the PACK flexible production line for this project:
Automatic Circulation and Precise Scheduling:An automated circulation system composed of over 100 AGVs/AMRs achieves efficient flow between different workstations through a hybrid navigation method using magnetic strips. The CRMS system receives and processes commands from various workstations in real-time, ensuring precise coordination of material handling.
Bidirectional Signal Transmission and Operational Control:AGV/AMR realizes bidirectional signal transmission with the PLC system, ensuring smooth operations when entering and leaving workstations. At manual operation stations, "pull cord signals" and "release signals" are used to schedule vehicles, reducing manual intervention and improving operational efficiency. Additionally, AGV/AMR can provide real-time feedback on operational status, optimizing the production workflow.
Online Charging and Continuity of Production:Each workstation is equipped with charging points to ensure that AGV/AMR devices can operate online for extended periods, enhancing production continuity and stability. The charging system is designed to support stable operation of AGV/AMR even under high load conditions, further improving overall production efficiency.
The AGV/AMR is controlled by a microcomputer, offering a long lifespan, strong performance, high scalability, and flexible scheduling. The CRMS system features both manual and automated operation modes, allowing for flexible switching according to different process requirements. This flexibility ensures the precision and efficiency of material supply, enabling optimal production alignment whether in automated stations or manual operation areas.
AGV/AMR is compatible with various types of material carts and can adapt to different sizes and weights of material transport needs. Additionally, the system is equipped with safety protection measures such as anti-static devices and emergency stop functions, ensuring the safety of operators and equipment throughout the production process.
AGV/AMR can operate at ultra-low speeds, allowing it to work alongside personnel and save turnaround time, significantly improving the production line cadence. High-quality components and a well-planned charging strategy extend the lifespan of AGV/AMR, reduce maintenance frequency, and ensure long-term stable operation of the production line.
With the support of 5G technology, the mobile robots can be remotely controlled in real-time. Additionally, the massive data generated by the robots can efficiently interact with the data center in real-time.
The mobile robots not only help the factory complete material handling efficiently, accurately, and flexibly, but also enable integrated management both inside and outside the factory, facilitating smart manufacturing improvements and digital upgrades.
The material storage information, inbound and outbound tasks, and on-site equipment are all centrally managed by the customer’s MES system, enabling real-time monitoring of material status inside and outside the factory.
