AGV Solution for Reach-Type High-Lift Forklifts in the Tobacco Industry Mar 19, 2025

Project Background


The tobacco industry is characterized by high material flow,multiple transportation stages,a high degree of automation and flexibility in production,and stringent requirements for information control and management systems.In recent years,major tobacco companies have been continuously adopting new technologies to enhance operational efficiency and control costs.As a hallmark of modern production,AGVs are well-suited to meet these industry demands.

This project aims to provide a fully automated,unmanned solution for a tobacco company,integrating storage,sorting,and distribution.The automation level is expected to exceed 90%.Additionally,to align with the State Council's "Made in China 2025" strategic plan,the project requires a significantly higher proportion of domestically produced equipment compared to imported products.





Implementation Challenges and Countermeasures


Due to site constraints,the project requires an increase in storage capacity.The temporary storage area is designed as a high-density storage zone,utilizing shuttle cars for storage and AGVs for transportation.The project primarily involves two key challenges:

Challenge 1: Efficient Warehouse Scheduling in a High-Density Storage Area with Limited Space
To address warehouse space limitations and optimize inbound and outbound efficiency,a customized Warehouse Management System (WMS) with multiple rule-based strategies was implemented.This system manages multi-level orders across provinces and cities,handling multi-SKU,multi-batch attributes.It streamlines order initialization,order consolidation,inventory allocation,picking strategies,and shipping strategies,significantly improving inventory efficiency.
Challenge 2: High-Precision AGV Handling of Shuttle Cars

There are very few successful industry cases of AGVs handling shuttle cars,mainly due to the minimal gap between the shuttle car and its rail.The AGV must place the shuttle car with millimeter-level accuracy.Additionally,the plant layout leaves only 2.7 meters of space for AGV movement.To overcome these challenges,a custom reach-type laser-guided forklift AGV was designed.The vehicle's mechanical structure was modified,and precise load distribution calculations ensured a compact yet stable design.The smaller body facilitated accurate positioning,while enhanced positioning sensors and an improved control system ensured millimeter-level precision.


Customer Value


This project deployed six reach-type laser-guided forklift AGVs working in coordination with shuttle cars.Manual layer-switching was replaced with automated AGV operations,significantly increasing workshop intelligence and automation while reducing labor intensity.The Yufeng intelligent scheduling system effectively addressed challenges such as high material transport volume,low efficiency,and inaccurate handling of manual forklifts.

This also enhanced workplace safety and eliminated the conventional reliance on stacker cranes or lifts to interface with shuttle cars,enabling cost-effective intelligent upgrades for the tobacco industry.


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