In the non-ferrous metal industry, high-temperature melting workshops,
complex production lines, heavy material handling and other scenarios
have long been facing high labor costs, high operational risks, efficiency
bottlenecks and other pain points. With the breakthrough of AGV
(automatic guided vehicle) technology and the deep integration of
industrial Internet, unmanned handling system is reconstructing the
logistics system of non-ferrous factories, and promoting the traditional
manufacturing to intelligent logistics 4.0. This paper analyzes how AGV
through technological innovation and scene adaptation, realize the
non-ferrous factory logistics cost reduction, efficiency, safety, low-carbon
four-fold change.
First, AGV technology breakthrough: crack the non-ferrous factory
logistics “neck” problem
The logistics scene of non-ferrous metal factories is characterized by
strong corrosion, high temperature, heavy load and other special
characteristics, which is difficult for traditional AGV to adapt to. The
new generation of AGV realizes full scene coverage by upgrading
three core technologies:
High-precision navigation technology: Combining laser SLAM (instant
positioning and map construction) and 5G+UWB (ultra-wideband
positioning), it realizes ±5mm-level positioning accuracy in complex
environments such as electrolysis workshops and melting and casting
lines, and can operate stably even in the face of metal reflection interference.
Multi-modal sensor fusion: equipped with infrared thermal imaging,
TOF depth camera, ultrasonic radar and other equipment, real-time
sensing of high-temperature molten metal tanks (temperature up
to 800 ℃), narrow channel obstacles, dynamic adjustment of obstacle
avoidance strategy, safety increased by 90%.
Heavy-duty flexible chassis design: Adopting omni-directional wheels
+ hydraulic lifting mechanism, a single AGV can load up to 10 tons,
suitable for copper anode plates, zinc ingots and other irregular heavy
materials handling, and increase the efficiency by 4 times compared with manual.
Case: After the introduction of 20 customized AGVs in a copper smelting
plant, the transfer time of copper plates in the electrolysis workshop has
been shortened from 30 minutes/trip to 8 minutes, which saves more
than 6 million yuan of manpower costs annually.
Second, the whole process reconstruction: AGV-driven upgrading of the
logistics network of non-ferrous factories
AGV is not an isolated device, its value lies in the deep coupling with the
production system, forming a **“material flow-data flow-control flow”
three streams in one** intelligent network:
Raw materials into the warehouse - batching - feeding link:
AGV is linked with WMS (Warehouse Management System) to automatically
dispatch vehicles according to the production plan, and accurately transport
raw materials such as copper concentrate and zinc roasting sand from the
three-dimensional warehouse to the batching warehouse, increasing the
inventory turnover rate by 35%.
Through RFID tags and visual identification, batch material tracking
is realized, avoiding fluctuations in composition caused by manual feeding errors.
Production process convergence link:
In the electrolysis workshop, AGV clusters carry copper cathode plates
to washing, stripping and packing stations in real time according to
MES (Manufacturing Execution System) commands, with a millisecond
response speed and a 22% reduction in the production line vacancy rate.
The digital twin platform simulates the logistics path and dynamically
optimizes the AGV scheduling strategy to reduce equipment waiting time.
Finished product out of the warehouse - factory distribution link:
AGVs and unmanned forklifts work together to complete the fully automated
transfer of zinc ingots, aluminum and other finished products from the
production line to the warehouse and loading area, with an average daily
handling capacity of 2,000 tons, doubling the efficiency compared to
the traditional model.
Third, value multiplication: AGV for the non-ferrous factory to bring four core benefits
The labor cost is directly reduced by 60%:
Replacing high-risk positions such as copper plate handling in
electrolysis workshop and ingot mold transfer in melting and
casting line, a single plant reduces labor cost by more than ten
million yuan per year on average, and at the same time, avoids
occupational health risks.
Increase production efficiency by more than 40%:
Through 24-hour continuous operation and accurate docking of
production beats, the problem of process congestion caused by
logistics delays is alleviated. For example, after AGVs came online
at an aluminum plant, the capacity utilization rate of the casting
and rolling line increased from 78% to 92%.
Double reduction of energy consumption and carbon emissions:
Path planning based on AI algorithms reduces the idle rate of AGVs
to less than 5%, and with lithium-ion fast-charging technology, the
average daily power consumption of a single vehicle is reduced by
80% compared with that of a fuel forklift, which helps enterprises
reach the goal of “double carbon”.
Data asset precipitation:
AGV operation data (such as load curve, fault code) real-time uploaded
to the industrial Internet platform for process optimization, equipment
predictive maintenance to provide a basis for decision-making, to promote
the factory into the “data-driven manufacturing” new stage.
Fourth, the implementation of the path: non-ferrous enterprises to deploy
AGV key three steps
Scene diagnosis and program customization:
For the logistics needs of different processes such as smelting, electrolysis,
casting, etc., choose latent, traction or forklift AGVs, and customize
high-temperature and corrosion-resistant shells.
System integration and digital twin verification:
Open up the interface between AGV scheduling system and MES, ERP, PLC
controllers, and use digital twin technology to simulate operation and
pre-judge potential conflict points (e.g., multi-vehicle intersection congestion).
Operation and maintenance system upgrade:
Establish AGV health management platform, realize fault warning through
vibration sensor and current monitoring, and ensure equipment availability
≥ 98% by combining AR remote operation and maintenance technology.
V. Future Prospect: AGV+New Technology Opens Infinite Possibilities
With the landing of 5G private network, edge computing and AI big model,
AGV will evolve in a more intelligent direction:
Group Intelligent Collaboration: Hundreds of AGVs negotiate paths
autonomously to form a decentralized scheduling network to cope with
sudden order fluctuations.
Human-machine cohesive operation: through 3D vision + force control
technology, AGV can safely shuttle through the manual work area, and even
collaborate with workers to complete complex assembly tasks.
Zero-carbon logistics closed loop: photovoltaic + energy storage system
provides green power for AGVs, and combined with carbon footprint tracking
technology, it creates a whole life cycle low-carbon logistics chain.
Conclusion
In the process of non-ferrous metal industry moving towards high-end, intelligent
and green, AGV unmanned handling system has changed from “optional”
to “mandatory”. By reconstructing the logistics system, enterprises can not
only realize short-term cost reduction and efficiency, but also accumulate
data assets, reshape the production model, and inject new kinetic energy
to participate in the global industrial chain competition. In the future, with
the technology iteration and scene deepening, AGV may become the core
hub of the “intelligent transformation” of non-ferrous factories, opening
up infinite possibilities for metal manufacturing.