Smart Fleet Management for 1.2 Ton Forklift AGVs
Problem Statement: A leading tire manufacturer faced bottlenecks in transporting heavy rubber rolls (1.2 tons) between the Iron MC machine and the Liner/Stock rails. The manual process was slow, prone to accidents, and difficult to track in real-time.
The Challenge:
- Heavy Load: Handling 1.2-ton payloads requires precise and safe navigation.
- Complex Traffic: Multiple AGVs operating in shared aisles with human workers.
- Legacy Integration: Need to communicate with existing machines via varied protocols.
Our Solution: Intelligent Traffic Control
WP Solution architected a comprehensive Fleet Management System that acts as the “Air Traffic Control” for the factory floor. The system manages job queues, calculates optimal routes, and prevents traffic jams using a dynamic node-based algorithm.
Key Features Implemented
- Dynamic Routing Algorithm: Calculates the shortest path and reserves nodes to prevent deadlocks.
- Real-time Visualization: A dashboard showing live AGV positions, battery status, and job progress.
- Collision Avoidance: Interlocks with Area Scanners (SICK) and localized E-Stops.
- Auto-Charging Management: Automatically sends AGVs to charging stations when battery levels are critical.
Technology Stack
| Technology | Role in System |
|---|---|
| C# (.NET) | Core logic for Traffic Manager & Pathfinding |
| MariaDB | Storing job history, error logs, and performance metrics |
| MQTT / TCP | Low-latency communication between Server and AGVs |
| Node-RED | IoT Gateway for connecting with legacy PLC machines |
Business Results
- ✅ 100% Traceability: Every movement is logged for process optimization.
- ✅ Zero Traffic Jams: Intelligent routing eliminated deadlock situations.
- ✅ 24/7 Operation: Automated battery management ensures continuous uptime.
Expert Insight: “The key to successful AGV implementation isn’t just the robot hardware; it’s the Traffic Logic. We designed a ‘Reservation Protocol’ where AGVs must request permission before entering any intersection, ensuring absolute safety.”
Looking to automate your internal logistics? Contact us at: wisit.paewkratok@gmail.com