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Project Case/
AGV Prototype Testing Project for the Electronics Manufacturing Industry

Project Overview

This project aims to deploy four AGV forklifts to replace manual labor in the automated transportation of semi-finished products from the 3F workshop to the 1F warehouse, establishing an efficient and traceable production logistics closed loop.


System Components

  • Hardware Modules: Dual-steering wheel drive system, LiDAR obstacle avoidance module, high-precision navigation module. Equipment dimensions: 1950×1150×1970 mm, load capacity: 2000 kg.

  • Software Platform:

    • RCS Dispatching System (real-time task allocation and traffic control)

    • ESS Monitoring Platform (real-time data dashboard and anomaly alerts)


Project Challenges

Facility Adaptation Challenges

  1. The existing elevator lacks AGV priority access, potentially causing transport delays during peak hours (estimated efficiency impact: 5%-8%).

  2. Structural columns in the 1F warehouse obstruct network signals, requiring additional relay equipment (estimated budget increase: ¥12,000).

Operational Transition Risks

  1. During the initial human-machine collaboration phase, employees may inadvertently enter AGV pathways (physical isolation barriers required).

  2. Foreign engineers involved in commissioning require bilingual (Chinese-English) operation manuals.

Hidden Investment Requirements

  1. Pallet standardization: 30% of existing pallets need magnetic strip positioning markers (total modification cost: ¥15,000).

  2. Air shower door integration testing requires a 2-hour production halt, potentially affecting daily capacity by approximately 3%.


Project Highlights

Intelligent Innovation

  1. Dynamic Path Planning: The RCS system calculates optimal routes in real-time, automatically rerouting around obstacles with a response delay of less than 0.5 seconds.

  2. Cross-Floor Coordination: AGVs autonomously call elevators via an IoT module, ensuring seamless floor map transitions.

Safety Redundancy Design

  1. Three-Level Protection:

    • LiDAR (3m pre-warning deceleration)

    • Mechanical collision strip (instant stop upon contact)

    • Remote emergency stop button

  2. Audio-Visual Interaction:

    • Automatic voice prompts when turning

    • LED warning light activation during nighttime operation

Expansion Compatibility

  1. Compatible with MES integration, enabling synchronized material delivery with production cycles in the future.

  2. Reserved 5G module interface for future remote maintenance support.


Project Benefits

Direct Benefits

  1. Efficiency Improvement: Transport time per trip is reduced by 36%, increasing the annual theoretical handling capacity by 12,000 tons.

  2. Cost Savings:

    • Replaces four manual transport workers, saving ¥576,000 annually in labor costs.

    • Reduces cargo damage rate by 0.3%, saving ¥85,000 annually.

Long-Term Value

  1. Management Upgrades: The ESS system enables real-time monitoring of equipment OEE (Overall Equipment Effectiveness) and generates fault prediction reports.

  2. Scalable Experience: Data accumulated from cross-floor AGV deployment serves as a reference model for smart upgrades in other factory sites.

Risk Control Gains

  1. Reduced Workplace Injuries: Mitigates safety risks associated with manual handling of heavy pallets, potentially reducing annual compensation costs by ¥50,000.

  2. Environmental Compliance: AGV energy consumption is 60% lower than diesel forklifts, aligning with carbon emission reduction policies.