AGV optimizes goods flow for even greater customer satisfaction
Long-standing partnership with Toyota Material Handling for a further step towards the future
An important instruction during the guided tour through the electronics production: keep a distance of 50 cm. Here is the reason: the automated guided vehicle system (AGV).
As one of the global technology leaders in ventilation systems, drive and control technology, we at ZIEHL-ABEGG are increasingly focusing on automation in the field of logistics. This enables us to achieve greater process reliability and make our internal material flow safe and future-proof. Today we are presenting an important milestone: automated industrial trucks from Toyota Material Handling.
Automated guided vehicle system (AGV) in the EC plant at ZIEHL-ABEGG ensures maximum reliability
It all began at the Kupferzell site: as part of the hall planning for the EC plant, a modern AGV system from Toyota was integrated in order to make processes more efficient and deploy employees in a targeted manner. The new hall was designed in such a way that automation solutions could be seamlessly integrated. Autonomous Toyota BT Staxio SAE160 Autopilot automated stackers are used to transport in-house production parts and reliably transport goods ready for dispatch from production to the dispatch area.
The focus: enabling humans and robots to work together safely.
The project was designed from the outset to enable safe interaction between people and robots. The automated stackers operate in a mixed mode, which means that they use the same routes as manual forklifts and a tugger train. This combination of different types of transportation is valuable, but also presents challenges that had to be overcome together in the initial phase. A key task was to create acceptance for the new AGV within the company.
The highlights of the driverless transport system
Load capacity and precision
The automated industrial trucks stack up to three pallets with a total weight of up to 1.6 tons and reach lifting heights of up to 4.7 meters.
Energy efficiency
Equipped with lithium-ion batteries, the autopilots charge independently and without special charging compartments. This reduces energy costs and CO₂ emissions.
Safety features
Laser navigation with reflector technology enables positioning accurate to the millimetre, while safety scanners detect obstacles and prevent collisions.
The automated industrial trucks relieve employees by taking over monotonous transportation tasks. This allows the workers to concentrate on more complex activities with higher added value. The success of the system is sustainable: in increased efficiency, reduced costs and improved process reliability.
In the ventilation technology area, the driverless transport system transports finished products to the high-bay warehouse and supplies selected production areas, which significantly speeds up the material flow in the air technology area.
Process reliability also in Künzelsau thanks to AGVs
Following the successful AGV integration in Kupferzell, ZIEHL-ABEGG is taking the next step with its proven automation partner Toyota Material Handling. In Künzelsau, an AGV system automates the internal material transport in electronics production. This was a particularly challenging project, as the internal material transport was to be automated in an existing hall and across several floors. The optimal solution: several identical Toyota Autopilots.
The system was implemented in a very short time, within six months of operation. The AGV largely automates internal material transportation. Manual journeys via elevators are now 95% redundant, saving working time and further increasing process reliability in the electronics production area.
Special requirements
Transport over 2.5 floors
Thanks to a scissor-type lift and transfer platforms with sensor monitoring, load carriers such as pallets, mesh boxes or EC circuit boards are transported safely between floors.
Automated control system
Employees can very easily trigger transport orders at defined stations. The AGVs automatically head for the relevant destinations.
Automation as a driver for innovation
ZIEHL-ABEGG consistently focuses on progress in order to master the challenges of modern logistics. In addition to efficiency gains, the gradual introduction of automated processes also strengthens the company’s innovative power in the long term.
In the coming years, ZIEHL-ABEGG will continue to invest in the optimization of its processes and take the next steps in the digital transformation. The strong partnership with Toyota Material Handling forms a solid basis for successfully implementing technological innovations in the field of logistics.
Toyota Material Handling (TMH) is the world’s leading brand in intralogistics. As part of Toyota Industries Corporation, which has around 78,000 employees worldwide and an annual turnover of over 25 billion euros, TMH offers a comprehensive portfolio of products and services. From energy-efficient forklift trucks of all drive types to state-of-the-art automated solutions that help optimize operations, reduce costs and increase customers’ overall productivity.
For more information, visit www.toyota-forklifts.de or go directly to the automation range at www.toyota-forklifts.de/automatisierung/.
Impressions of AGV projects
© Toyota Material Handling
© Toyota Material Handling