[New Energy] Case Study of a Photovoltaic Customer in Sichuan

Project Background

Project land area: 3,000 m²
Total storage locations: 17,278 

This project is located in Meishan, Sichuan. To promote Industry 4.0 transformation, the customer is set to build a smart factory and a modern warehousing and logistics center. The facility covers an area of 3,000 m² and is dedicated to the storage of photovoltaic cells. To address challenges such as high-precision storage, multi-carrier adaptability, and space constraints, Wayzim has developed a customized tote shuttle dense warehousing system and a stacker crane AS/RS. These systems support seamless integration between warehousing and production, enabling fully unmanned operations across the entire workflow from palletizing to outbound shipment.

17,278

Total storage locations

283 totes/h

Inbound/Outbound efficiency of the tote AS/RS

87 pallets/h

Inbound/Outbound efficiency of the pallet AS/RS

Customer Pain Points

Diverse carriers

A wide variety of product packaging and handling carriers lead to high compatibility challenges.

Severe storage pressure

Large inventory volumes in a constrained warehouse space make traditional warehousing unable to meet operational demands.

Complex, error-prone processes

From palletizing to shipment, the lengthy operational chain involves multiple links, and manual handling is prone to errors.

Solution

Based on the on-site surveys and product features, Wayzim deployed two Automated Storage and Retrieval Systems (AS/RSs).

Tote AS/RS: A tote four-way shuttle system is designed for the dense storage of partial pallets of totes. Depalletizing and palletizing robots automatically split and recombine mixed pallets. Full pallets are automatically transferred to the pallet AS/RS.

Pallet AS/RS: A stacker crane AS/RS is designed to store full pallets. Integrated with customized conveyors, strapping machines, and wrappers, the system supports automated transport and packaging for multiple handling carriers. The barcode recognition system ensures inbound/outbound accuracy and enables automatic order packaging and shipment.

Product Configuration

Double-reach Pallet Stacker Crane × 3

Tote Four-way Shuttle × 9

WMS /WCS

Automated Conveyor Lines

Solution Benefits

Improved palletizing efficiency

The tote AS/RS is equipped with multiple shuttles and vertical conveyors to dynamically handle complex inbound, outbound, bulk inbound, and bulk outbound scenarios. Depalletizing and palletizing manipulators automatically break down mixed pallets and recombine full pallets.

Stable conveyance and durable equipment

Customized conveyor lines adapt to diverse products and carriers and can effectively protect load carriers, extend the service life of key equipment, lower replacement frequency, and reduce maintenance costs.

Automated shipment

After an order is released, the system automatically performs palletizing, wrapping, and strapping, significantly improving shipment efficiency and lowering management costs.

Real-time equipment monitoring and management

The 3DMS supports visualized, three-dimensional equipment monitoring and rapid fault location, minimizing downtime and boosting operational efficiency.

Together Towards Tomorrow