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It ranks among the top five in China's tire industry and is the first private tire company listed on the A-share market. The Qingdao factory in China plans to improve the logistics efficiency of the rubber mixing workshop through the introduction of the unmanned forklift logistics system, realize the standardized, intelligent and flexible logistics mode in the workshop, and build a pilot demonstration project of intelligent manufacturing in the rubber tire industry.
Difficulty
1. How to solve the navigation problems in dynamic and complex scenes, high pollution, low visibility and environment?
The on-site environment is complex and changeable, with many equipment and personnel and cross-operation; The flat ground is low, and the presence of dust and smoke in the production environment leads to low visibility, which makes it impossible to use the traditional marked navigation method.
2. How to ensure production capacity, avoid production line congestion, and solve the rapid and efficient flow of materials?
The flow of rubber material in and out of the warehouse is large, with a production capacity of 200 pallets per hour, which requires high efficiency of the dispatching system.
3. Optimize and improve the cluster scheduling efficiency of AGVs.
The scheduling strategy of 5 AGVs and 50 AGVs is different, including the difference of routes, some pick-up/place/cargo points are in the shape of "points" (the site is relatively open), and some are in the shape of "lines" (the site is very congested), coupled with the constraints of the overall space, it is a great test for the cluster scheduling strategy.
Solution
Through 53 laser SLAM unmanned forklifts, AGV realizes the automatic flow of master rubber training, final rubber training, raw rubber and small powder in the mixing workshop; At the system level, the AGVS dispatching system is used as the main body to open up the data link of MES, WMS, RFID and other systems to realize the closed-loop of the entire production logistics information and the visual management of personnel and equipment.
Core technology
1. Cluster scheduling strategy
The cluster application of 53 unmanned forklifts without identification navigation, the self-learning and adaptive environment is more intelligent, and the multi-vehicle time window is used to ensure the fewest vehicles and the highest efficiency
2. B-spline rail body control
The vehicle adopts B-spline to ensure that the arc transition of the car continues to run without pausing or slowing down, and based on the bionic concept, multiple vehicles can approach infinitely in a small space without colliding.
Benefits
1. The annual cost is saved by about 8 million yuan
Save 20 manual forklifts, more than 50 forklift workers and operators, effectively achieve the double carbon goal of energy saving and consumption reduction, and reduce carbon emissions by more than 15% every year;
2. Reduce the hidden danger of accidents by 90%.
The management of the entire on-site operation is standardized and standardized, and the working environment is greatly improved, which significantly improves the comfort of employees' work and improves their health, and reduces safety risks to 0 accidents throughout the year.
3. The production capacity has been increased from 900 tons/day to 1600 tons/day
Integrating MES system, RFID Internet of Things system, inventory management system, unmanned forklift handling system, and digitally driven by the whole process of the entire production operation, it has built a digital and transparent factory, and has been listed as a provincial and municipal intelligent manufacturing pilot demonstration project.
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.