Project Overview

This project aims to automate the entire storage and logistics process, including raw material entry, production line delivery, and finished product shipment, to meet the semiconductor industry's demand for efficient, accurate, and safe logistics management. This is a turnkey project where the contractor is responsible for the design, manufacturing, installation, and commissioning processes. The project is expected to help the client achieve benchmark operations in semiconductor storage and logistics through intelligent upgrades.

Hardware Equipment:

• 3D Racking System: Theoretical storage capacity of 20,016 positions, compatible with four different box sizes.

• Box Stacker Machines: 4 units, with an individual machine efficiency of 170 boxes/hour.

• Double-layer Conveyor Lines, Layer-changing Elevators, and Lifting Transplantation Machines.

• CTUs for Material Boxes (4 units), Lifting AGV (1 unit), and Associated Workstations.

Software Systems:

• Warehouse Management System (WMS)

• Equipment Control System (WCS)

• Robot Dispatching System (RCS)

• Integration with the client's SCM system to ensure data interoperability.

• Covered Scenarios: Raw material inbound/outbound, finished product inbound/outbound, empty box recycling, and cross-floor logistics.

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Project Challenges

High Implementation Complexity:

1. The 3D warehouse must meet ground load-bearing requirements (≥5000 kg/m²) and flatness standards (surface undulation ≤3mm/m²), which makes civil engineering modifications challenging.

2. Cross-floor AGVs must interact with elevators, requiring precise communication and path planning coordination.

System Integration Challenges:

1. The integration of WMS with the client's SCM system needs to ensure real-time data consistency.

2. Coordination between multiple devices (stackers, AGVs, conveyors) can be affected by network delays or task conflicts.

Operational Dependency:

Core components of AGVs and stackers (e.g., servo motors, batteries) require regular maintenance, raising the technical skill requirements for the client's personnel.

Project Highlights

Technological Innovations:

1. Double-Layer Conveyor Design: Improves space utilization and transport efficiency, supports vertical layer-changing transportation.

2. High-Precision Equipment: The stackers use Schneider servo motors with laser positioning (repeated accuracy ±5mm), and AGVs support QR code navigation with multi-level safety protection.

3. Intelligent System: Seamless integration of WMS, WCS, and RCS enables full-process automation and real-time monitoring.

Flexible Adaptability:

1. Compatible with four types of material box sizes (max dimensions 600×400×230mm), with shelf and equipment designs leaving room for future expansion.

Safety & Reliability:

1. Stackers and AGVs are equipped with mechanical collision protection, emergency stop devices, and audio-visual warning systems for multi-level safety.

2. The electrical control system uses modular programming, supporting fault self-diagnosis and rapid recovery.

Energy-Efficient & Green:

The AGVs use lithium iron phosphate batteries, supporting automatic charging and low-energy operation.

Project Benefits

Efficiency Improvement:

1. Warehouse efficiency increased by over 30%, with stacker combined cycle efficiency reaching 232 boxes/hour (theoretical value).

2. Automated AGV delivery reduces manual handling, improving production line response time by 50%.

Cost Optimization:

1. Reduced reliance on manual labor, with an expected 20%-30% saving in labor costs.

2. Space utilization improved by 40%, reducing the need for warehouse space.

Management Upgrade:

1. Real-time inventory visualization, supporting safety stock warnings and overdue material reminders.

2. Data-driven decision-making to optimize production cycles and logistics paths.

Risk Control:

1. Full-process automation reduces human errors, enhancing material traceability.

2. Lower equipment failure rates, with the contractor offering 24-hour response service during the warranty period.