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简体中文 Still worried about the workshop logistics like the morning rush hour subway congestion?Imagine: forklifts and AGV on the ground to steal the road, the material pile up to walk with difficulty, multi-vehicle production line a change of type on the chaos ... ... This scene, Toyota and Hisense have experienced! But now, they rely on a set of ”air highway” ---Turning Suspension Conveyor LineIn addition, the logistics efficiency has been raised to 30%, and the space has been saved to 2,000 square meters! Today we will break up and talk about how to customize this ”air conveyor belt that can turn” in the end is reliable.
First, the pain point directly hit: the traditional ground logistics ”three mountains”
- Space fights
What was Toyota's workshop like before? The production line is crowded with AGV, forklifts, material racks, people and equipment like playing ”bumper cars” - not to mention the low transportation efficiency, collision risk is also a high thief. - It's jammed when you change the model.
Hisense produces more than 70 types of air conditioners in one line, and the specifications of the parts are very different. Ground logistics like ”dead brain”, simply can not keep up with the rhythm, not move to send the wrong material or pile up a mountain. - a major energy consumer drags its feet
With 15 fuel forklifts + 30 old AGVs, carbon emissions alone are 1,200 tons more a year! How is this logistics? It is simply ”burning money and the earth”.
To put it bluntly: the ground is saturated, unresponsive, and energy-intensive - forcing companies to ask for space in the sky!
Second, the air break: how to customize the suspension line to see how to do it
▶ Spatial Magic: ”Uprighting” the flat road network”
Toyota's solution is brilliant - use theAluminum tracks build an ”overpass” at a height of 3-5 meters.The 2-kilometer-long track connects the stamping, welding and assembly workshops like a blood vessel. The key in the three ”can”:
- Can turn.: 90°, 180° corners to flexibly bypass equipment (refer to Hisense's 3-meter narrow aisle program)
- able to climb slopes: ≤ 60 ° slope directly across the floor (chain pitch selection of 250mm single point load-bearing 60kg to be stable)
- stretchable::modular designLengthen the track at any time (Toyota's new welding station only adds a branch)
Effect? Directly freeing up 2,000 m² of floor space!The forklift aisle was reduced from 3 meters to 1.5 meters, saving enough space to open another production line.
▶ Intelligent brain: let the material ”recognize its own way”.”
It's not enough to have tracks.The core is in the algorithmic scheduling! To give two chestnuts:
- ToyotaAI dynamic scheduling system: Assembly line running out of parts, the nearest available material truck is assigned within 30 seconds, automatically bypassing congested roadways.
- Hisense'sAirtac distribution: Match 200 parts into a set of hanging air conveyor, faster than bulk distribution 40%
put the emphasis on: The track is the torso, the algorithm is the soul! Customization must require open PLC interface, convenient docking MES/WMS system.
Third, the parameters of life and death: customization must stare at the 4 hard indicators
Don't be fooled by manufacturers! These parameters directly determine success or failure:
| Parameter type | case of stepping on a pitfall | Guide to avoiding the pit |
|---|---|---|
| turning radius | A furniture factory used 1.8m radius to cause the chain to be scrapped in half a year | Minimum radius = 2 x trolley length(1.2m trolley needs to be ≥ 2.4m) |
| Chain Pitch | Electronic factory with 150mm chain lifting 10kg chip box shaking broken | 150mm (8kg load capacity) for light load and 250mm (60kg load capacity) for heavy load. |
| driving power | Auto plant motor overheating shutdown costs millions | according to the formulaN=k_e-(T_max-v)/6120Calculate, k_e<0.93 change gearbox immediately |
| Safety Redundancy | A factory wire rope breaks and damages equipment | retrofittingtertiary protection: Physical anti-swing + electronic fence + software dual system |
lesson learned through blood and tears: A pharmaceutical company did not calculate the powder loss factor, the actual conveying capacity of only 70% designed.Material CharacteristicsMust be written into the contractThe
Fourth, the industry customization differences: car factory VS food factory play
The needs of different industries vary greatly, and customization is like ”tailoring”:
- Automobile plants (e.g. Toyota)::
- To accuracy: ±2mm positioning error-proof parts (by LIDAR + vision navigation)
- Playing with Flexibility: Multi-tasking delivery with one vehicle (delivering part A and then folding back to deliver part B)
- Food factory (with reference to Hisense experience)::
- Anti-pollution: full stainless steel chain plate + food grade PU belt
- Fast cleaning: tracks are pre-plumbed for rinsing gun connections
You see, the same hanging line - automobile factories as ”precision instruments” to engage in, food factories as ”hygiene standards” management!
Fifth, the cost of the code: so customized to save 20%
Don't be an ingrate! Keep an eye on these hidden additions::
- Substitution of non-standard parts: Use 200mm standard chain + reinforced spreader, save 150k compared to customized 250mm chain
- Subtracting functionality::
- Non-explosion proof distinction optional explosion proof certification (markup 30%)
- Slope > 5 ° split drive, than the overall climb to save 45%
- Maintenance buried hooks::
- Requirements for signing the agreement3-year warranty on core components(motor/gearbox)
- Modular design makes changing the chain like changing a battery - where to change where it breaks, no waste of money.
put at the end
After ten years of factory planning, my biggest realization is this.Workshop logistics upgrade is not to buy equipment, but to change thinking. Toyota and Hisense's success, the essence of the two-dimensional plane competition into a three-dimensional spatial game - when others are still entangled in the ground how to swing, they have been in the sky to build a high-speed road network.
A final word of caution.: Suspension lines aren't as expensive as Toyota.Command hardware with algorithms, take data to drive decisionsAfter all, every square meter and every minute of labor time saved is real money. After all, every square meter of land and every minute of labor saved is real money!
