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Warehousing and Flexible Distribution Logistics System for Zoomlion Assembly Workshop
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Application Scenarios
Focusing on the excavator assembly section of construction machinery, an automated warehousing and logistics system has been established, with separate zones for large and small components. The system incorporates Miniload carton‑type vertical warehouses and stacker‑crane‑based high‑bay storage for oversized parts, along with integrated conveyor lines, multiple types of AGVs, PTL light‑directed picking, robotic picking, and gantry robots, seamlessly linking warehousing with the production line to achieve fully automated, closed-loop material delivery across the entire process.
1. Miniload automated storage and retrieval system ↔ Precision component picking area
The WMS work order triggers automated outbound operations from the small‑item vertical storage system, enabling the picking and tray‑picking of precision components such as valve bodies, seals, and sensors. This ensures on‑demand replenishment of assembly materials and facilitates the automatic return of empty containers to the warehouse for reuse in a closed-loop cycle.
2. Automated storage and retrieval system for large components ↔ Structural component machining station
The stacker automatically handles the storage and retrieval of heavy structural components such as boom arms, frames, and hydraulic tubing. These parts are then conveyed to the pre‑assembly stations via heavy‑duty forklift AGVs, and automated loading and unloading is achieved with a gantry robot.
3. AGV flexible delivery ↔ Complete machine final assembly line
On light‑load AGV‑driven synchronous production lines, material replenishment is precisely synchronized with the production takt. Once a complete unit is finished, an AGV fleet handles the transfer of finished goods and returns excess materials to storage, enabling fully automated, unmanned logistics flow throughout the plant.
Application Results
The project integrates digital twin, IoT, and big data technologies to establish an intelligent logistics management system for the plant. By leveraging a multi‑functional automated high‑bay warehouse, intelligent sorting, and coordinated AGV operations, it achieves full‑process unmanned handling of both large and small materials—covering storage, distribution, and loading/unloading. Furthermore, it seamlessly connects WMS, ERP, and MES data systems, enabling dynamic inventory scheduling and digital monitoring of warehouse operations. Following implementation, Warehouse space utilization increased by 600% ， Overall production efficiency improved by 300%. , significantly replacing manual operations, reducing material errors and labor costs, and enabling a shift in logistics management from experience‑driven to data‑driven, resulting in exceptionally high customer satisfaction.
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