Transforming Internal Logistics in a Tier 1 Automotive Plant with AMR and Smart Fleet Management

โจทย์ที่ได้รับ: A Tier 1 automotive parts manufacturer needed to revamp its internal logistics for transporting raw materials and finished goods (weighing up to 500 kg) between the Automated Storage and Retrieval System (AS/RS) and the production lines. The legacy process relied heavily on human-driven forklifts, which posed a high risk of workplace accidents and completely lacked real-time data connectivity between the warehouse operations and the manufacturing machines.

ความท้าทาย: Deploying automated guided vehicles (Reach AMRs) in this specific environment presented significant challenges. The designated AMR routes intersected with internal factory roads actively used by logistics trucks. Furthermore, the existing production machines were legacy systems devoid of modern communication networks. To enable the AMRs to safely pick up or drop off material hoppers, precise handshake signals (Interlocks) had to be established to halt the machine’s conveyors and actuate safety gates prior to any AMR intervention.

แนวทางการแก้ปัญหา (Solution)

Our team engineered a comprehensive system architecture utilizing a “Gateway & Orchestrator” approach, effectively bridging the gap between IT (Information Technology) and OT (Operational Technology):

  1. Retrofit & Machine Interfacing: We installed Mitsubishi PLCs (FX5U) as interfacing units at critical legacy machine points (Hopper Changer, FG Station, Empty Basket). This allowed us to extract physical I/O operational statuses and convert them into digital data.
  2. Smart Fleet Management: We developed a robust Backend Server using Node-RED acting as an API Gateway. It receives high-level job orders in JSON format via REST API from the client’s central Orchestrator (MIF System) and translates them into dynamic routing coordinates for the AMRs over TCP Sockets.
  3. Automated Traffic Control: We implemented an automated traffic light and safety gate system integrated with our PLCs. This system intelligently halts regular factory vehicle traffic whenever an AMR is approaching the road crossing.
  4. Real-time Dashboard: A modern frontend interface was built using Vue.js 3 (Composition API) to monitor AMR live locations, cycle times, battery statuses, and PLC interlock signals in real-time.

System Architecture Diagram

เทคโนโลยีที่ใช้

  • Node-RED & Node.js: Acts as the core Orchestrator and API Gateway, handling REST API requests, processing FIFO job queues, and communicating with the MySQL database.
  • Vue.js & Tailwind CSS: Powers the interactive monitoring dashboard for the central control room, providing real-time fleet visualization and historical job reports.
  • Mitsubishi FX5U PLC: Functions as the Machine Interfacing Unit, translating legacy machine I/O into standard Modbus/TCP data for the central server.
  • REST API & JSON: Forms the standard communication protocol ensuring seamless cross-platform integration between the client’s core system and our AMR Fleet Manager.

ผลลัพธ์ที่ได้ (Business Impact)

  • ✅ Zero Accident Traffic: The automated synchronization between the AMRs, traffic lights, and safety gates eliminated accident risks at the factory’s internal road intersections.
  • ✅ Seamless IT-OT Integration: Legacy manufacturing machines can now “communicate” flawlessly with the smart AS/RS and AMRs, significantly reducing human error in material handling and dispatching.
  • ✅ High System Reliability: The Fleet Manager architecture operates 24/7, autonomously handling complex job queues, auto-charging loops, and dynamic route adjustments with minimal human intervention.

เกร็ดความรู้จากหน้างาน: When managing the queue for the material hoppers, relying solely on the Backend Server (Node-RED) to memorize the queue state introduces a single point of failure (e.g., during power outages or server restarts). Instead, we designed a “PLC-Driven State”. The server simply reads the array data directly from the PLC and applies a “Find Max Value” algorithm to determine the exact FIFO sequence. This approach guarantees industrial-grade robustness and ensures no data loss occurs on the factory floor.

ต้องการที่ปรึกษาระบบ Automation? ติดต่อเรา: wisit.paewkratok@gmail.com | Line: wisit.p