Synersight is a company specialized in the design, manufacturing, and commissioning of Autonomous Vehicles, AGVs, and AMRs, with a strong track record of over 4,000 operational units across 250 clients and nearly 500 completed projects. Committed to our mission of optimizing production processes through innovative technologies that promote sustainability and safety, we are proud to present a success story in the automation of logistics flows for FPT Bourbon Lancy, a subsidiary of IVECO GROUP, which manufactures engines for heavy-duty vehicles.
In this project, FPT Bourbon Lancy sought to automate four logistics flows using Karakuri structures, where the AGVs were required to precisely control the exchange of boxes between the vehicle and the structure, ensuring safe and efficient operation. Synersight developed a customized solution that not only addressed these challenges but also significantly improved the integration of automation systems, ensuring seamless operation and effective traffic control between different brands of autonomous vehicles.
Project Needs and Challenges
FPT Bourbon Lancy needed to automate four specific logistics flows in their plant, enabling the AGVs to manage the automatic exchange of packaging with Karakuri structures installed on their production line, optimizing both operational efficiency and process safety. The key challenges included:
- Precise Packaging Exchange: The AGVs needed to control the exchange of packaging transported on carts and those on the Karakuri structures at the preparation and consumption points, ensuring that each box moved at the right time.
- Integration with Karakuri Structures: The AGVs needed to interact with the Karakuri structures accurately, using sensors to ensure the boxes were exchanged correctly.
- Signal Management and Multibrand Traffic: In addition to controlling internal flows, it was essential to coordinate the traffic of Synersight‘s AGVs with those from other brands operating in the same plant, preventing collisions and optimizing workflow.
Solution: Design and Technological Adaptation
To address these challenges, Synersight designed a customized solution that included:
- Adapted SMUs with Direct Connectors to PLC: Four AGVs from the SMU range were adapted, equipped with connectors on their rear that connected to the vehicle’s PLC, enabling the AGVs to control the photocells of the carts to manage the necessary signals for box exchange.
- System Integration for Communication: The Karakuri structures were equipped with reflectors and photocells. The VSystems fleet manager handled the signal combinations from the photocells present on the Karakuri and carts, executing the “shoot” (start signal) to ensure the AGV advanced in parallel to the structure for controlled box movement.
- Automation of the Exchange Process: At the preparation station, the AGVs would pick up full boxes and drop off empty ones, and then perform the opposite operation at the consumption station, exchanging full boxes for empty ones. Using photocells, a system was set up to verify the correct conditions at each exchange position before the AGV could move forward.
- Multibrand Traffic Control: Synersight developed a traffic management system that allowed the AGVs to communicate indirectly with autonomous vehicles from other brands. When an AGV from another brand entered a shared area, it sent a signal that stopped Synersight‘s AGVs, and vice versa, preventing collisions and improving coordination in the plant.
Results and Benefits Achieved
The implementation of this customized solution brought significant benefits to FPT Bourbon Lancy:
- Efficient Box Exchange: The adaptation of the SMUs to handle photocell signals and the integration with the Karakuri structure allowed for fast and precise box exchanges, significantly reducing cycle times and increasing operational efficiency.
- Improved Safety: By effectively managing traffic and controlling signals from different systems, any risk of collision between AGVs from different brands was avoided, greatly enhancing plant safety.
- Customization and Adaptability: The customization of the SMUs, with direct connectors to the PLC and adaptation of VSystems software to control signals, demonstrated Synersight‘s ability to tailor its solutions to the specific needs of the client, ensuring smooth, uninterrupted operation.
“Synersight’s AGVs responded flexibly to our project, ensuring a smooth transition. Synersight was able to adapt to our requirements easily, and by working together, they achieved this integration.
Additionally, the integration with the Karakuri systems was no easy task. We were looking for 100% automation (no human intervention) and very high precision, up to 5mm, to ensure flawless delivery.
These two conditions were essential to guarantee our production,” says Richard Labonde, Head of Logistics Media at FPT Bourbon Lancy.
“Since this implementation, we are very satisfied with the results and the management of the AGVs, as well as their communication with our other AGVs,” says Richard Labonde, Head of Logistics Media at FPT Bourbon Lancy.
Conclusion
The success of this project underscores the importance of a comprehensive and collaborative approach to industrial automation. Challenges that initially seemed insurmountable, such as creating a customized solution and coordinating vehicles from other brands, were overcome through creative design and tailored solutions.
The integration of the SMUs with Karakuri structures and the coordination with autonomous vehicles from other brands have allowed for optimized operational efficiency and enhanced safety, reaffirming Synersight‘s commitment to innovation and excellence in industrial process automation. Synersight‘s experience demonstrates that with proper planning and collaboration with the client, it is possible not only to meet but exceed initial objectives, achieving automation that adds real and tangible value to operations.
