Smart Manufacturing at EP’s Anji Factory
In the heart of the industrial sector, a new chapter was poised to unfold for EP Equipment, a global leader in material handling equipment manufacturing. As the curtains rose, the world witnessed an extraordinary facility symbolising the company’s dedication to the Industry 4.0 revolution. This factory was not merely a production line; it stood as a testament to the relentless drive for innovation and the seamless integration of advanced technologies.
This state-of-the-art factory, with an annual production capacity of 300,000 vehicles, showcases how automated robots and digital technologies are revolutionising manufacturing.
Automation Technology at the Core
EP’s lithium-ion workshop is vital for producing lithium batteries at this plant. With a capacity of 3.5GWh, the workshop manufactures batteries that boast long lifespans and quick charging capabilities. These batteries feature EP’s proprietary Battery Management System (BMS) and require no maintenance, highlighting EP’s leadership in utilizing lithium-ion batteries for material handling equipment. The workshop employs a four-axis robot and three six-axis robots to enhance automatic intelligent assembly, intelligent testing, and to ensure the highest quality, reliability, and stability of the batteries.
Intelligent Automated Vehicles: X-Movers
EP’s commitment to intelligent manufacturing is exemplified by the utilization of X-Movers, a fleet of XPG/RPG handling robots designed for seamless material transportation within production facilities. These X-Movers, equipped with laser navigation systems, excel in efficiently moving materials between floors and production lines. By integrating these intelligent movers into their manufacturing processes, EP ensures a streamlined workflow, minimizes delays, and maximizes productivity. This strategic deployment of intelligent robotics underscores EP’s dedication to staying at the forefront of manufacturing innovation.
DAS: Digital Autonomous System
EP’s factory utilizes the Digital Autonomous System (DAS), integrated with their ERP system, to manage material storage locations, inventory, and handling automation. The XPG/RPG X-mover models use DAS to autonomously transport materials between floors and production lines. In the paint shop distribution centre, X-Movers with DAS identify incoming materials by code scanning and weighing, updating storage locations accordingly. DAS tracks frame storage locations and commands the trucks to retrieve required parts for assembly lines. X-Movers stack frames in distributed warehouses during non-operating hours based on DAS scheduling. DAS manages distributed storage of large and small parts, with robots locating parts using identification codes. At the distribution centre, industrial cameras work with DAS to direct movers for unloading and material handling tasks. The integrated DAS system enables EP to enhance each production element and build on its competitive production strength.
Welding and Painting: Automation Excellence
The welding shop within EP’s factory stands as a pinnacle of automated manufacturing processes. Equipped with fully automated welding lines capable of producing 35 sets per shift while reducing manual labour requirements by 75%, EP has set a new industry standard for efficiency and productivity. Spanning an impressive 20,000 square meters, the paint shop is another area where automation excels. The entire painting process, from shot blasting to inspection, is completed with automated digital control. This not only enhances the surface quality and durability of the forklifts but also ensures optimal performance.
Entering a New Era of Manufacturing
The Anji Factory North District stands as a beacon of EP Equipment’s vision for the future of manufacturing. Visitors are captivated by the precision, efficiency, and technological prowess that permeate every corner of the factory. Here, the boundaries between human and machine blur, creating harmonious progress. This achievement marks a significant milestone for EP Equipment and serves as an inspiration for the entire industry. The future of manufacturing has arrived, and EP has paved its way boldly.
