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It is a large-scale first-class tire enterprise in China, mainly producing "Qianjian" brand automobile tires, with an annual production capacity of more than 6 million pieces and more than 1,000 specifications and varieties, and is the tire manufacturer with the most complete specifications and varieties in China. The first phase of the company's project puts forward the demand for logistics transformation in the automatic distribution of the molding-vulcanization process, and promotes the deep integration of big data and industry through the introduction of intelligent equipment, so as to build a full-chain intelligent system. Through on-site investigation, AGV Robotics analyzed the difficulties in the transformation of traditional tire factories and gave corresponding countermeasures.
Customer needs
After the fetal embryo is formed, it is necessary to automatically buffer and automatically send it to vulcanization, and it is necessary to solve the problem of automatic warehousing and storage after the fetal embryo forming, replace the manual handling from molding to vulcanization with automated logistics, and avoid the backlog of fetal embryos in the vulcanization area, and at the same time, the vulcanization process needs to use the fetus embryo to automatically supply the vulcanizing machine to replace the manual moving embryo to the vulcanizing machine, and the finished tire after vulcanization needs to be automatically sent to the next process with AGV.
Solution
1. Fetal embryo cache storage
The manipulator grabs the tray of the tire embryo from the cloth pocket truck and puts it into the storage conveyor line, and each set of manipulator is equipped with a set of visual inspection system to automatically detect the thickness of the tire, and after the grabbing is completed, the tire embryo is automatically sent to the vertical warehouse operation area through the conveyor line.
2. Fetal embryo out of the warehouse - vulcanization
60 customized knapsack AGV trolleys complete the automatic handling of tire embryos out of the warehouse to the vulcanizer production line.
3. Engineering tires are stored in storage
16 laser SLAM unmanned forklifts complete the storage of engineering tires into the general shelf warehouse, and carry them from the shelf warehouse to the vulcanizer production line.
4. Closed-loop data management
Provide WMS, WCS, AGVS system, according to the needs of the vulcanizer in the MES system, generate handling tasks, and the AGV will directly send it from the vertical warehouse outlet to the vulcanizer or store it in the vertical warehouse first; When the stacker crane needs to take the fetal embryo from the vertical warehouse, the MES system will send the outbound instruction information to the vertical warehouse WMS system, and the vertical warehouse WMS system will issue the library instruction to the WCS system, and the stacker crane will carry out the fetal embryo out of the warehouse.
Core technology
1. Navigation in highly dynamic and human-machine mixed scenarios
On the basis of laser SLAM navigation, multi-sensor is combined to enhance the stability of positioning and navigation, and the understanding of scene semantics is added.
2. Optimization of cluster scheduling system
The trolley AGV and the unmanned forklift are used in a narrow channel to achieve efficient control and scheduling.
3. Optimize the production scheduling plan and reduce inventory
Through the combination of vertical warehouse, stacker, various manipulators and AGVs, the logistics mismatch caused by the difference between the molding and vulcanization processes in the tire industry is solved, and the production scheduling plan is optimized to the greatest extent, thereby reducing inventory.
Benefits
From factory construction planning, simulation, product design, manufacturing, to product provision, on-site remote operation and maintenance, the full-stack logistics solution of AGV's digital factory runs through the whole life cycle of intelligent manufacturing of tire enterprises, and finally realizes the start-up rate of the enterprise's vulcanizing machine from 89% to 95%, the pass rate of the machine inspection of finished tire products from 93% to 97%, the overall efficiency of the molding and vulcanization production line by more than 50%, the saving of 37 labor, the output value by 50%, and the product quality to 120%.
In the digital factory solution cooperated by 20 leading rubber enterprises, through the introduction of AGV and AIDT digital twin platform solutions in the process of mixing-half parts-molding-vulcanization-finished products-automatic loading and delivery, the problems existing in the industry such as increased labor costs, difficulty in recruiting workers, and low information level have been solved, and the whole process automation, full-field informatization, and full-logistics intelligent connection of the enterprise have been realized.