20. Estudos de caso: Racks de Fluxo AGV na fabricação de veículos elétricos?

The Engineering Shift: Why “Welded” Fails in EV Logistics

In automotive manufacturing, particularly within the Linha de Prensas de Estampagem and Powertrain Assembly sectors, the dynamic loads are extreme. A common failure mode we observe in converted EV plants is the fatigue fracture of traditional welded racks. When a AGV Escondida (Underride AGV) lifts a rack carrying a 500kg chassis component, the upward force combined with the lateral shear during acceleration creates a unique stress profile.

Unlike static warehousing, mobile robotics require a Rigid Frame that can withstand constant vibration. Spacedas utilizes a Fully Bolted Structure using Q355 High-tensile Steel. This allows the rack to “flex” microscopically without cracking, absorbing the kinetic energy of the AGV.

Case Study A: The “Zero-Forklift” Battery Pack Line

The Scenario: A Tier-1 EV manufacturer was struggling with line-side congestion. Their battery modules (weighing approx. 180kg each) were delivered via forklift to the assembly station. The sheer size of the forklifts meant wide aisles were required, eating up valuable production floor space. More critically, a recent “near-miss” involved a fork tine scratching a module casing.

The Solution: We deployed a fleet of custom Automated Pallet Warehousing racks designed for heavy payloads.

• Structure: Reinforced Q355 steel base to handle the concentrated load of the AGV lifting plate.
• Segurança: Integrated anti-slip pads and mechanical interlocks to prevent the battery pack from shifting during the AGV’s emergency stop (E-stop) maneuvers (0.5g deceleration).
• Resultado: By switching to Underride AGVs, aisle width was reduced by 45%. The “Zero-Forklift” zone policy was successfully implemented, eliminating collision risks.

Case Study B: SPS and Karakuri for Line-Side Delivery

The Scenario: In the final assembly shop, the Set Parts Supply (SPS) area required rapid turnover of small fasteners and trim parts. The manual exchange of empty and full boxes was causing downtime, affecting the Takt time.

The Solution: Spacedas implemented a Karakuri AGV Flow Rack system (Shooter Rack).

This system utilizes a mechanical “Shooter” mechanism. When the AGV docks at the assembly station, a lever is physically triggered by the docking station, releasing the lock. Gravity then slides the KLT Boxes (standard automotive containers) from the mobile rack directly onto the workstation’s flow rails.

The Engineering Magic: No motors, no batteries on the rack itself. Just pure mechanics. This significantly lowers maintenance costs compared to powered conveyor transfers.

FAQ: AGV Racks in Automotive Manufacturing

How do you handle ESD for sensitive EV electronics?	For BMS (Battery Management System) and PCB components, we use conductive castors and ESD powder coating. The rack ensures a ground path with resistance between 10^5 and 10^9 ohms, preventing static buildup that could fry chips.
Can these racks handle the weight of a full EV chassis?	Yes. Our Q355 High-tensile steel frames are engineered for heavy payloads. We perform Finite Element Analysis (FEA) to ensure the rack can withstand the specific point-loads exerted by the AGV’s lifting mechanism without deformation.
Are your racks compatible with typical automotive KLT boxes?	Absolutely. Our flow lanes and shelf heights are customized to fit standard VDA KLT boxes (RL-KLT, R-KLT) commonly used in the European and Asian automotive supply chains.
What happens if the AGV stops suddenly?	We calculate the center of gravity (CoG) for fully loaded racks to ensure stability during emergency braking (up to 1g deceleration). We also install mechanical stops and lips on the shelves to prevent parts from sliding off.
Do you support “Milk Run” logistics?	Yes. Besides underride racks, we design towable carts (tugger train frames) that can be hitched to AGV tractors for milk-run delivery cycles throughout the plant.