III. Successful Case | Heavy-Duty Conveyor Lines and RGV Production Line Enable an Industry-Leading Core Smart Factory

IV. Project Challenges Wheels Project

Although the number of devices in this project was not large, the design and production of heavy-duty non-standard equipment posed a major challenge. Among 85 conveyor devices, there were 60 types, nearly all unique. The RGVs needed to handle 25 tons, reaching an industry peak.

Project Challenge 1: Non-standard equipment requires customized design and manufacturing according to the requirements of each production stage.

Project Challenge 2: 25-ton heavy-duty RGVs not only need transfer functions but also lifting capabilities.

V. Solutions

• Non-standard equipment was designed by technical personnel after fully understanding client requirements, ensuring that all devices met the needs of each workstation and production stage.

  The project involved various complex devices, making it technically challenging to design, produce, install, and commission within a limited timeframe to allow the automated production line to operate on schedule.

  

  

  

• The 25-ton heavy-duty RGV lifting function was necessary to interface with client equipment.

  Because the heights of production equipment varied, the transfer RGV had to adapt to different heights. Handling 25-ton materials posed a significant challenge for the lifting function. EFX engineers conducted 3D simulations to test lifting and lowering functions in different environments and confirmed the use of screw-lift mechanisms to ensure stability and meet load requirements.

  
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VI. Project Delivery

Successful Delivery, Win-Win Outcome

The project was successfully delivered, achieving very satisfactory results. The RGV equipment helped the client improve storage management in terms of quality, cost reduction, and efficiency enhancement.

Through this project, EFX achieved new technical breakthroughs and parameter upgrades, resulting in a mutually beneficial outcome for both parties.

III. Successful Case | EFX Helps Taiyuan State Grid Metering Center Renovate Old Warehouse, Creating a New Operating Model

IV. Project Challenges Wheels Project

As an old warehouse renovation, operations could not interfere with the client’s ongoing production. Existing racks could not be removed, limiting working space. EFX conducted on-site surveys and measurements to develop feasible demolition, installation, and commissioning plans. After thorough understanding and client confirmation, the project involved dismantling the old stacker cranes, installing new cranes, and setting up track switches. The project faced three major challenges:

Project Challenge 1: How to dismantle and install stacker crane mechanical equipment?

Project Challenge 2: How to integrate new stacker cranes with the old warehouse while meeting dual-rail requirements?

Project Challenge 3: With wireless communication prohibited by the client, how can the rotary stacker crane achieve automated communication?

V. Solution

• Mechanical Dismantling and Installation: Fully Manual

  As shown in the figure: Due to limited space in the front area of the warehouse, where conveyors and robots were already installed, mechanical lifting equipment such as cranes or forklifts could not be used. All dismantling and relocation were performed manually using hand hoists and winches.

  

• Adding Overhead and Ground Track Switches for Automatic Rail Switching

  The client required stacker cranes to be able to switch aisles. Track switch devices were added at the warehouse ends, allowing cranes to change rails and move to different aisles automatically.

  Adding Optical and Carrier Communication for Real-Time, Automated Operation

  Since rotary stacker cranes are usually best suited for wireless communication, but the client prohibited wireless systems, EFX implemented a dual communication system: optical communication for straight sections and carrier communication for rail-switch sections. This non-standard dual communication ensures cranes remain online continuously and operate automatically, meeting the client’s requirements.

  

  

VI. Project Delivery

Old Warehouse Successfully Renovated, Phase II Signed Early

After delivery, the client was highly satisfied. The renovation addressed previous pain points and challenges, ensuring the core operational functions were met. The stacker cranes operate smoothly, maintaining daily outbound requirements.

Thanks to joint efforts, Phase II renovation has already been initiated, with the contract signed and production underway.