Dec 01,2023
Expanding the Power Tool Track, Damon Helps Production Line Logistics Intelligent Upgrade
At present, under the guidance of Industry 4.0 strategy, industry’s intelligent upgrading is becoming the only way for the sustainable development of all walks of life. Logistics runs through the entire production process, industry’s intelligent upgrading cannot be separated from the digital collaboration of logistics. Without digital logistics, intelligent manufacturing cannot be achieved. Therefore, the logistics digitization demand of manufacturing enterprises under intelligent manufacturing is prominent, and the importance of improving intelligent production efficiency is self-evident.
As an important branch of intelligent manufacturing field, the power tool industry is also facing the problem of how to effectively connect the production line and logistics, and create digital supply chain management. As an industry leader, an internationally renowned power tools and garden tools overall solution provider finds in the capacity expansion that the existing material transfer between production processes was over-dependent on labor, resulting in low operational efficiency and high labor costs; In addition, with the continuous increase of the its business orders, the demand for improving the utilization rate of factory space is becoming more and more urgent.
Hand in hand, solutions are newly upgraded
In view of this, in 2020, this enterprise's lithium new energy power tool production base Phase II project in Nanjing officially started construction, with a total investment of 1 billion yuan and a total construction area of 152,000 square meters. The new factory chooses to join hands with Damon Intelligent Logistics, introduces logistics automation equipment and production information technology, comprehensively upgrades the logistics supply chain system, significantly reduce logistics and labor costs, enhance the enterprise's intelligent manufacturing strength, and jointly create a new benchmark for intelligent manufacturing in the industry!
The project includes several production lines such as motor and other key parts, platform tools, riding tools, handheld power tools, etc. Manufacturing, assembly, injection molding, total assembly and other processes require intelligent logistics systems to be connected in series. By deploying a 2km i-G5 modular intelligent carton conveying system and 300+ sets of core equipment for pallet conveying, Damon seamlessly connects the raw material warehouse, line side warehouse, production line and finished product warehouse, while supporting a number of continuous and reciprocating vertical lifters to achieve material flow across three floors, supplemented by automatic equipment such as film winding machine, distacking and stacking manipulator, scanning and weighing. Through the major links of "raw materials warehousing - whole layer distacking - temporary storage at line side warehouse - production line temporary storage" and "finished products transportation - complete pallet stacking - temporary storage of exwarehousing - loading and shipping", a double cycle of materials and finished products in and out of the warehouse is formed.
To face challenges, innovation highlights occur
In the face of new industry challenges, Damon team chooses to meet the difficulties, based on rich experience in logistics system solution planning and professional project management and service team full deployment, starting from customer needs considerately, put a lot of effort to customize and test non-standard new products, to match the actual needs of project, to help customers solve the problems one by one.
1）Anti-falling of extra-wide special-shaped pallets
Some of the customer's products are huge in volume and size, and it is difficult to design the scheme. Damon has specially created a roller conveyor line suitable for large, ultra-wide and ultra-high pallets for customers. Taking into account the net height of the warehouse, in order to ensure finished products’ high-efficiency transfer, Damon reduces the overall height of line body equipment to 80mm, and installs anti-falling supports on both sides of pallet, and at the same time, uses power rollers instead of conventional motors to drive, to prevent the whole pallet materials from falling during the transportation process.
2）The whole floor turnover carton’s automatic distacking
Damon specially sets up four automatic distacking and stacking robots to cooperate with the i-G5 conveyor line, connecting the pallet three-dimension warehouse, the carton three-dimension warehouse, realizes three’s cross-warehouse linkage. Damon's robotic automatic distacking and stacking solution can be widely compatible with 10+ types and different specifications of the turnover box, the pallet material can be distacked for the whole layer, the distacking beat efficiency can reach 600 cartons /h (15 seconds/cycle), a whole layer of 4-5 turnover boxes can be transported to the conveying line body at the same time and put into line automatically, breaks the tradition of conventional turnover box one by one put on line, and realize unmanned material transfer.
3）Material cross-floor conveying efficiency is improved
Damon also innovates for the project to plan the front and back double-station carton high-speed reciprocating vertical conveyor, which can enter and exit two boxes of goods at one time, with high load capacity and vertical conveying efficiency, which can easily cope with large volume heavy objects, suitable for small footprint, high flow requirements, and application scenarios with entry and exit, compared with the single-station lifter, the processing capacity can be doubled. It can guarantee the highly efficient and stable operation of materials across layers.
4）The finished product conveying is stable and waterproof
Some finished products are small in volume and easy to fall after stacking，at the same time, in order to meet the higher waterproof requirements of customers' finished products exported overseas, after stacking, the whole pallet finished products will first pass through the automatic film wrapping machine integrated by Damon and then enter the warehouse, the system processing capacity can be up to 45 pallet/h to ensure the absolute safety and stable conveying of finished products.
After the project is officially put into operation, it can form efficient coordination between logistics storage and distribution business, resources and equipment, realize unmanned operation and intelligent management, reduce manual dependence while improving production logistics efficiency, and comprehensively improve product quality and production capacity.
1）i-G5 conveying line body processing capacity: 2000 cartons/hour
2）Carton-type vertical lifter efficiency: 600 cartons/hour
3）Pallet conveying line body processing capacity: 112pallets/h
4）Pallet vertical lifter efficiency: 130 pallets/hour
Deeply understanding industry’s characteristics and actively exploring customer needs are the key to Damon's ability to deliver high-quality projects. In the future, Damon will continue to develop the intelligent manufacturing industry, provide customized intelligent logistics system solutions for customers in the subdivision field, in the digital wave, promote the intelligent upgrading of logistics in the factory, create new incremental fields for the manufacturing industry, and accurately empower the high-quality development of the industry.
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