Project Overview (Objective)

The goal of this project is to achieve automated transfer on the heavy truck and bus final assembly line, enhancing the level of automation in assembly. The system will support mixed-line production for buses (up to 12 meters/12 tons) and trucks (up to 6 meters/7.5 tons), with flexible fixture/tooling exchange to accommodate various production requirements.

Logistics Requirements

• Transport Objects:
  Buses (7000KG/10500KG) and trucks (7500KG), with compatibility for varying body sizes (up to 12 meters in length).

• Operational Mode:
  Two AGVs (Automated Guided Vehicles) will operate in synchronized pairs, carrying vehicle chassis forward or backward. Once at the designated station, the AGVs will stop and await manual assembly.

System Composition

• AGV Equipment:

  • Main Line AGVs: Dual AGVs synchronized to carry a total load of up to 12 tons.

  • Auxiliary AGVs: Supporting unit with a load capacity of 1 ton.

  These AGVs are capable of moving forward, backward, and laterally, with adaptability for high and low workstation switching.

• Central Dispatch System:
  The central dispatch system will wirelessly coordinate multiple AGVs via WiFi, handling path planning and task control.

• Online Charging System:
  The side-charging mechanism allows automatic docking of the charger with the AGVs, enabling continuous operation.

• Manual Control Button Box:
  After assembly at a workstation, the manual control box triggers the release command for the AGV.

Project Challenges

The heavy-duty nature of the truck and bus, with their longer dimensions and heavier weights, presents challenges in handling stability. Using a single AGV for transport risks uneven loading, causing tilting or instability (front or rear tipping). Achieving smooth transfer during the AGV's load-bearing process is a key challenge.

Project Highlights

• Dual Vehicle Synchronized Control:
  The front and rear AGVs work in coordinated power, ensuring stable transportation of the vehicle body.

• Tooling Compatibility:
  The system allows for quick changes of the positioning fixtures to accommodate different production needs for buses and trucks.

Project Benefits

• Efficiency Improvement:
  The use of AGVs for automated transportation reduces manual handling. This ensures better control of assembly cycle times, increasing line efficiency by over 30%.

• Flexible Production:
  The ability to quickly replace fixtures supports mixed-line production for multiple vehicle types, lowering modification costs for the production line.

• Safety:
  Human operators are only involved in the assembly stages, while AGV paths and workstations are isolated, reducing the risk of human-machine interference.

• Digital Management:
  The central dispatch system provides real-time monitoring of AGV status, integrating data with the MES (Manufacturing Execution System) for transparent production management.

This project focuses on enhancing production efficiency, safety, and flexibility through the use of synchronized AGV systems, automated control, and seamless integration with digital management systems, driving improvements in both assembly operations and overall workflow.