The hottest way to help traditional manufacturing

How good is it to help traditional manufacturing enterprises move towards industry 4.0 intelligent warehousing system

Abstract: when it comes to logistics, your first impression must be express delivery, but the optimization of internal logistics in traditional manufacturing industry is equally important to improve production efficiency and realize industry 4.0

when it comes to logistics, your first impression must be express delivery, but the optimization of internal logistics in traditional manufacturing industry and then loosening the nut are equally important to improve production efficiency and achieve industrial 4.0

as a leading enterprise in the domestic security field, Hikvision is deeply touched by this

what are the benefits of intelligent warehousing

in June 2014, Hikvision's security industry base in Tonglu, Zhejiang Province was officially launched. In the second half of 2015, the first phase of the base was completed and put into operation, covering an area of about 370 Mu and a construction area of about 260000 square meters. The intelligent warehousing and in plant logistics solutions in the base are provided and implemented by its subsidiary Hangzhou Haikang Robot Technology Co., Ltd. (hereinafter referred to as "Haikang robot")

one of the most well-known is Hikvision intelligent storage robot

according to fugaoxiang, director of Hikvision mobile robot advanced manufacturing industry group, the base currently uses more than 800 AGVs, scattered in four raw material warehouses, one semi-finished product warehouse, two finished product warehouses and six factory workshops, covering the AGV needs of warehouses, warehouses and production lines. While meeting the storage and internal logistics needs with a daily output value of nearly 100 million yuan, it effectively saves 58% of labor use and improves the work efficiency by 84%

introduction of three components

fugaoxiang, Hikvision intelligent storage robot system is composed of AGV (intelligent storage "wear-resistant TORLON Pai robot with unparalleled performance in lubricating environment), RCS (robot scheduling system) and iwms (intelligent storage management system) Three parts

after receiving the order, AGV will go to the shelf where the corresponding goods are stored, jack up the shelf, and then pull the shelf to the picker. After picking, the robot will drag the shelves to the shelf area for storage, which greatly reduces the running distance between people and goods, and significantly improves the picking efficiency of goods

agv is not a new thing. It has been developed for more than 50 years, and has gradually derived three mainstream schemes:

magnetic stripe scheme: the earliest AGV robot adopted the magnetic stripe scheme, which requires laying magnetic stripes on the ground first, and the robot moves along the magnetic stripe to realize point-to-point handling. Its advantage is low cost, but low flexibility, not intelligent enough

laser scheme: AGV robots using laser scheme can be divided into two kinds: one is to establish a small car through laser ranging combined with SLAM algorithm. "An executive of an insurance company said that the whole set of driving path map does not need any auxiliary materials, and the degree of flexibility is higher, which is suitable for global deployment; The other is reflector navigation, that is, laser reflectors with accurate positions are installed around the driving path of AGV. AGV determines its current position and direction by emitting laser beams and collecting the laser beams reflected by the reflectors at the same time, and realizes AGV navigation through continuous triangular geometric operations

the advantages of laser navigation are accurate positioning, no positioning facilities need to be laid on the ground, and the driving path of the robot can be flexible, but the manufacturing cost of laser navigation AGV is high, and there are certain requirements for the environment

QR code scheme: grid QR code graphics need to be arranged on the ground of the warehouse, and its map is equivalent to a large go chessboard. The robot usually navigates through inertia, and then corrects when passing the QR code. The two-dimensional code navigation is not interfered by sound and light, but there are special requirements for the coding material of the two-dimensional code, as well as strict requirements for the accuracy and service life of the gyroscope

fugaoxiang introduced that at present, AGV with magnetic stripe scheme still accounts for the largest market share, because it has a long history, while laser and two-dimensional code schemes have only been developed in the past three to five years. Hikvision AGV adopts a QR code scheme, similar to Amazon's Kiva. Fugaoxiang believes that considering various factors, the QR code scheme will be the development trend in the future

it is reported that mr-q7-lr100a (2.0) is the AGV with the largest load capacity of Hikvision so far, with a rated load capacity of 1000 kg, a maximum running speed of 0.8m/s, and a endurance time of more than 8 hours under full load. Fugaoxiang said that AGVs with a larger load can also be customized according to customer needs

if AGV is compared to the limb of intelligent storage system, RCS is the brain of the system, which is responsible for task allocation, scheduling, operation and maintenance of all robots. RCS adopts a variety of scheduling algorithms, which can realize the optimal allocation of tasks, multi robot path planning and robot traffic management, so that robot clusters can work together in coordination, cooperate with each other without affecting each other, and give full play to the maximum efficiency

rcs is also responsible for monitoring the operation status of robots, deciding whether to carry out specific project maintenance according to the historical situation and current status of each robot, and reasonably arranging needed robots to charge independently and supplement energy in combination with the operation status of the charging station and the current task execution; Record, analyze and summarize the alarm information of all robots, timely notify the operation and maintenance personnel, and give corresponding inspection and treatment suggestions to ensure the reliability of the whole system

a major indicator of the intelligence of this brain is the maximum number of AGVs that the system can schedule in a single warehouse

recently, cainiaolu Huiyang warehouse was officially put into use, with more than 100 single warehouse AGVs, known as China's largest smart warehouse. But in fact, as early as 2016, the number of single warehouse AGVs in Hikvision's No. 2 finished product warehouse has reached 115. According to Fu Gaoxiang, the maximum number of single warehouse AGVs in Tonglu base has reached 160

in the express industry, Hikvision also launched Hikvision intelligent sorting robot. In the projects that have been implemented, the maximum number of single bin sorting robots has reached more than 330, and even more than 600 in the simulation environment. Fu Gaoxiang said that storage robots and sorting robots are the same in terms of traffic management and scheduling

iwms

iwms integrates a variety of storage optimization technologies, which can realize random storage of materials and improve the utilization of storage space; Dynamically adjust materials in hot and cold areas in real time to improve delivery efficiency; Through the analysis of historical operation data, we can also mine the association between materials and formulate corresponding warehousing strategies to improve the efficiency of warehousing; It is interconnected with video surveillance to view the on-site operation dynamics in real time

how does the system work

how does Hikvision intelligent warehousing system work

warehousing of raw materials

Fu Gaoxiang introduced to Lei Feng that after the truck delivered the raw materials, there was a suspension area at the gate of the warehouse. Warehouse workers use hand-held PDA to scan the delivery note to complete the receipt and posting, and scan and bind the pallet indicator with the information of each consignment of goods. The indicator displays the real-time processing status of goods through the light color. For example, red represents items that need to be inspected, while blue and green represent upper high-rise shelves and single-layer shelves respectively

fugaoxiang specially pointed out that two major elements should be paid attention to when goods are put into storage: one is weight; The second is volume. Weight and volume determine what kind of shelves are used for goods. After the goods are delivered, the volume and weight parameters must be obtained first, and then iwms will automatically analyze the remaining storage area and the weight of the goods in the warehouse, and allocate the optimal position according to the established warehousing strategy

at the same time, AGV transports empty shelves to the warehousing workbench, and a large number of goods with heavy single pieces are transferred to the single-layer shelves by forklift, so as to improve the shelving efficiency and reduce the handling volume of workers; Goods with small quantity and light weight are placed on multi-storey shelves to maximize the use of storage space

raw material delivery

mes system can automatically sense what materials are missing on the production line and communicate them to iwms system for docking. The iwms system will divide the material demand into several orders, and each order is divided into several order lines. AGV will automatically pull out the corresponding shelf according to the order line, and then manually pick the required raw materials from the shelf and send them to the production line, realizing the requirements of "goods to people" and "goods to people", and improving the delivery efficiency

raw material transportation

raw materials are transported out of the warehouse through turnover box + cage car. If the production line is on the same floor, AGV will directly carry the cage car to the production line; If it is on different floors, the RCS dispatches the hoist to realize the cross floor handling of the cage car. After reaching the target floor, it is connected and transported to the production line by another AGV

finished products warehousing

workers scan the packaging information of finished products and place it on the single-layer shelf. After the code holder is completed, call AGV. It is the same as the transportation of raw materials. If the target warehouse area is on the same floor, the finished products are transported by AGV and directly warehoused; If it is on different floors, the RCS dispatches the hoist to realize cross floor handling and warehousing, and updates the inventory information after warehousing

finished goods delivery

finished goods delivery means that the customer has placed an order and needs to find the goods in the order. For example, if the customer puts down five cameras, AGV will go to the warehouse and pull out these five cameras. If the five cameras are not on the same shelf, it will pull out several shelves respectively and let the workers choose the five cameras

as for the position before the shelf is pulled out, the position to be placed, the position to be put back, and which AGV completes which task are automatically assigned by the system. The position of the shelf coming out and going in is not necessarily the same, and the system will automatically optimize it. The warehouse is divided into cold zone and hot zone. The cold zone is for infrequent goods, and the hot zone is for frequent goods. The hot zone is close to the workbench, while the cold zone is relatively far away, so as to achieve the shortest total access distance

what are the requirements

the system is good, and the key is to be able to use it

for the majority of small and medium-sized manufacturers, they do not have the same strong supply chain management capabilities, infrastructure and it capabilities as Hikvision. Is such an intelligent warehousing system applicable to them

fugaoxiang introduced to Lei Feng that generally, Haikang will require suppliers to affix one-dimensional codes on the boxes and minimum packages of goods, and the goods need to be scanned, bound and unbound when entering and leaving the warehouse. For smaller manufacturers, if suppliers cannot meet their needs, they can choose to paste one-dimensional codes in the warehousing and inspection links

at the level of system docking, Fu Gaoxiang said that when cooperating with customers, they do not dock according to the standard interface every time, but need both sides to complete the development together. If the manufacturer's iwms system is unqualified, the enterprise needs to further develop some functions, and Haikang also needs to develop corresponding functions according to the other party's system

fugaoxiang emphasized that what Haikang requires customers to have is a certain degree of it ability, rather than what kind of system they must have. For Hikvision, whether it is connected to the ERP system of the enterprise or not, the intelligent storage system can operate independently. Customers need to figure out whether to connect or not and to what extent. As long as the customer has the corresponding IT capabilities, Hikvision can connect with its MES system through buttons, apps and other forms. The specific form of connection depends on the actual operation of the site

if the fixture of the tensile testing machine is an important part of the instrument, the customer's