Focus on AGV industry for 18 years
Focus on AGV industry for 18 years
The motorcycle manufacturing industry is at a critical stage of rapid development, facing increasing market demand and diversified product lines. This project urgently requires improvements in production efficiency and process flexibility. Traditional manual handling and assembly methods are struggling to keep up with high-intensity production tasks and are prone to errors that may lead to quality issues or production bottlenecks. Therefore, the introduction of JASUN Intelligent Smart Logistics becomes a key factor in upgrading the assembly line.
By enhancing flexibility and efficiency through intelligent material handling and automated logistics delivery, this system not only demands precise route planning but also needs to synchronize with the existing production cadence. At the same time, it ensures coordinated work across multiple processes and workstations, thereby significantly improving the overall automation level of the production process.
The motorcycle assembly line includes several processes (e.g., front fork assembly, rear swing arm assembly, final assembly, etc.). The AGVs must be capable of precisely docking and automatically releasing at different workstations and work areas to ensure smooth operation across multiple production stages.
The production line needs to support the concurrent manufacturing of various product types, requiring high flexibility in the AGVs’ adaptation. The AGVs must be capable of handling complex movements such as forward motion, backward motion, and rotation on the spot, ensuring seamless transitions between different product assembly stages.
The production cadence is fast, requiring the AGVs' movement to be highly synchronized with the workstation cadence. Additionally, the system needs to switch flexibly between a rigid mode and a flexible mode to accommodate different production requirements and optimize efficiency.
CASUN designed and implemented a highly intelligent smart logistics solution for the complex needs of this vehicle assembly line project:
◆ Flexible and Forced Control Modes: Depending on the production line requirements, the AGVs support two modes. In forced mode, the AGVs move synchronously every 80 seconds according to the rhythm set by the main control cabinet. In flexible mode, the AGVs can complete the process transfer of individual equipment based on manually triggered signals, allowing flexibility to meet different production needs.
◆ Intelligent Route Planning and Accurate Docking: The AGVs automatically travel along the set route and achieve precise positioning through ground-sensing magnetic strips, with error control within ±10mm. Whether traveling counterclockwise on the main line or clockwise with the front forks or rear swing arms, the AGVs use right-angle turns to ensure smooth direction changes and accurate docking.
◆ Automatic Charging and Short Circuit Protection Mechanism: The AGVs feature an intelligent fast charging function. During charging, the connection between the running brush and battery is automatically disconnected to prevent short circuits. In non-charging areas, the charging plates remain unpowered, further ensuring safety. Additionally, the AGVs have a battery life of over 10 hours, meeting long-duration production needs.
◆ Abnormal Alarm and Record Function: The AGVs are equipped with an abnormal alarm system that records and ranks fault information, assisting maintenance personnel in quickly troubleshooting issues and ensuring efficient operation of the equipment.
The AGVs' efficient operation across multiple workstations, combined with the flexible mode, significantly enhances production efficiency while meeting the demands of multi-variety, co-line production. This ensures that the system can handle various product types seamlessly and adapt to changing production requirements.
The intelligent charging protection feature ensures safety during the charging process, reducing downtime and extending the lifespan of the equipment. This system minimizes risks and enhances the overall reliability of the AGVs, ensuring that they can operate efficiently over long periods.
The abnormal alarm and logging functionality improves the maintainability of the AGVs, allowing for quick identification of issues and minimizing downtime. This ensures the continuity and stability of production, making the system more reliable and less prone to disruptions.
Lower the investment in fixed equipment, create a flexible production line, and improve scheduling flexibility; increase the yield rate and accuracy.
Achieve intelligent in-house logistics by optimizing warehouse locations, paths, and task assignments, and implementing full-process information management.
Accurately collect data on material efficiency, frequency, utilization, etc., and use the analysis to improve processes and enhance efficiency.
