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In the polyethylene warehouse of a large state-owned coal chemical enterprise, 32 5G unmanned forklifts have autonomous navigation, intelligent obstacle avoidance and automatic charging, completing the automatic warehousing, intelligent storage management and automatic delivery of chemical materials, and improving the overall operational efficiency and stability of the warehouse. The successful implementation of the company's "5G unmanned forklift" warehousing intelligent project has completed the ice-breaking of Huainan City's "5G Industrial Internet" application project in the field of coal chemical industry, and the project has been awarded2023 Anhui Province "5G Industrial Internet" Innovation Application Award。
Project Overview
In view of the pain points of the industry such as poor flexibility, high cost and application constraints in the traditional operation mode of the warehouse, the state-owned enterprise polyethylene warehouse plans to accelerate the formation of new quality productivity through high-end and intelligent logistics transformation, and create a new situation of high-quality development and efficient operation of the enterprise.
Solution
Through 32 sets of 3T counterbalanced forklift AGVs, the automatic warehousing of 140 tons/hour of capacity of 140 tons/hour of cargo stacking, the automatic outbound delivery and loading efficiency of 195 tons/hour capacity of 4 packaging lines are realized, as well as the automatic storage and sorting of shared pallets, and the operation process of empty pallets and empty pallets are supplemented in time according to the packaging situation of the production line.
1. Create an unmanned handling mode for production
32 forward-moving stacking AGVs, the maximum load of the model is 3T, the lifting height is 3M, using a new generation of laser dynamic mapping and navigation technology, the technology can scan the scene in real time dynamic mapping, at the same time, based on the leading high-precision positioning and servo control perception technology, unmanned forklifts can be stable, efficient and safe for cargo stacking operations;
2. Build a digital management platform
Through the 5G WMS warehouse management system, the original manual input data deviation is improved, and the whole process of real-time collection of information such as production business, finished product inbound and outbound business, and delivery business is realized. Through the WCS warehouse control system, the task control of the packaging line, the storage area in the warehouse and the loading area outside the warehouse is realized, as well as the linkage control of the loading manipulator and the loading and conveying equipment;
3. The first 5G unmanned forklift cluster project in the chemical industry
In the 5G private network environment, 32 unmanned forklifts solve the problems of high switching delay and easy disconnection of industrial APs in the past, effectively reducing the disconnection rate by more than 90%. At the same time, the AGVS scheduling system is deployed in the 5G industrial edge cloud to achieve real-time, stable and scalable data and ensure accurate and reliable production.
Difficulties and countermeasures
Difficulty 1: High throughput, 40 seconds to drag off the line, 20 minutes to fill a car
对策：设立排队等候点，工作时间段，自动补全排队点，一台叉车AGV搬完货物离开后，剩余的叉车AGV会立马进入搬货点搬运货物，保证在取货点的高吞吐搬运（该功能已有十余个项目验证）。优化核心算法，包括使用人工智能算法合并多任务，保证车辆尽量减少“空跑”。
Difficulty 2: Navigation and positioning, the stack is 5m high, and the forklift AGV is all surrounded after the pile, how to achieve autonomous navigation and positioning?
对策：艾吉威自研的激光导航系统具备高精度的实时场景重构的能力。因客户现场场景动态变化，引用导航地图实时变化来应对。AGV动态更新、实时感知运行环境，及时变换路线及运行节拍，静态地图与动态地图高效融合，应对完整任务可能发生的环境变动，实现环境千变万化，AGV“随机应变”。
Difficulty 3: How to avoid the risk of cargo dumping?
对策：货叉上安装感应传感器，自主感知降低安全点，同时检测托盘与叉齿之间是否出现严重倾斜；采用错位堆叠方式，保证堆叠的稳定性。
Difficulty 4: Cluster scheduling, safe and efficient control of the cluster operation of 50 automatic forklifts
对策：艾吉威AGV的集群调度能力已经过实践项目验证，在包装行业有40台AGV的高吞吐运输案例，在轮胎行业有70台AGV的集群调度案例，在海外有70+AGV集群调度案例。
Core technology
1、三维激光场景重建技术
Establish a high-precision map, improve the ability of environmental anti-interference, and improve the operation stability of each unmanned forklift;
2、AGVS集群控制的自组织能力
The self-learning ability of task planning technology ensures that the vehicle does not "run empty", reduces the blockage and deadlock of unmanned forklifts, and improves the operation efficiency of multiple vehicles;
3、深度学习技术
Combined with the depth information of the laser, the goods are accurately positioned, the soft bag stacking is solved, and the end fork picking accuracy is improved;
4、运动控制算法
Realize the smooth and high-precision operation of unmanned forklifts, complete the warehousing and handling of finished products, and realize the warehousing and delivery of finished products to the exact location, with a position accuracy rate of 100%;
Project Effectiveness
The person in charge of the company said that through the introduction of 5G intelligent forklifts, it has effectively improved the efficiency of warehousing and reduced the work intensity of warehouse personnel, comprehensively calculated to save labor costs of 1.5 million yuan/year, and has a significant effect on improving inventory accuracy and reducing inventory backlog rate.