The individually designed automated guided vehicle system (AGV) transforms in-house logistics and also improves efficiency, plant availability and occupational safety. The fleet masters complex special functions and high payloads without any problems - even in demanding plant environments with narrow passages, tunnel underpasses and crossing (sham) traffic. The automation was triggered by the high product diversity, increasing demands on flexibility and safety as well as an increasing damage rate during manual transportation. "We wanted to optimize all processes holistically and create an end-to-end coordinated material flow - from the pressing plant to final production and shipping," explains Andreas Raab, Project Execution & Engineering Europe at RHI Magnesita. The transport robots were precisely adapted to the plant-specific conditions. Tight space and different floor conditions as well as safety-critical interfaces required precise planning and high-performance vehicle technology.

Automated area linking: AGVs in heavy-duty use

The AGV fleet connects all production areas: two transport vehicles are used to set up the presses with molds weighing up to 6.5 tons. Three others reliably transport the shaped refractory bricks - with individual weights of up to 16 tons - to the tunnel kiln. Further vehicles take the products for reworking or directly to the high-bay warehouse. The overall system was designed for maximum throughput and optimum integration into the existing plant layout using detailed simulation models. The benefits: significantly reduced set-up times, minimized downtimes and consistently high product quality.

High system availability thanks to full service

RHI Magnesita has implemented an extensive service package from EK robotics to ensure that operations run smoothly at all times. This includes the strategic stocking of spare parts on site, proactive and corrective maintenance measures as well as a 24/7 hotline with individually coordinated response times. Further joint automation projects are already being planned.