2.4.2026 / 5-minute read
AGV Lift with Ultra-Low Scissor Platform for Automotive Door Manufacturing
Overview
This urgent need for a custom vertical transportation solution that would act as an integrated node within a fully automated logistics system, rather than a standalone piece of equipment.
Basic Parameters
| Category | Parameter / Specification |
|---|---|
| Main Specifications | |
| Rated Load Capacity | 5,000 kg |
| Platform (Car) Interior Size | 3,000 mm (W) × 2,200 mm (D) × 2,800 mm (H) |
| Travel Height | 9,900 mm |
| Number of Stops | 2 Stops & 2 Stations |
| Running Speed | 30 m/min |
| Structure & Materials | |
| Main Structure Material | F200 Section Steel + 120×60×5mm Square Tube |
| Platform Main Frame | 160×80×4mm Rectangular Tube |
| Platform Deck Panel | 5 mm thickness |
| Platform Guide Rail | T90 |
| Counterweight Guide Rail | TK5A |
| Top Frame Material | 200×100×8mm Rectangular Tube |
| Top Panel | 10 mm thickness |
| Lifting Chains | 20A-2 |
| Buffer Type | Polyurethane |
| Safety Gear | Anti-Drop Device |
| Control & Safety System | |
| Control Modes | Manual & Automatic |
| PLC & Frequency Inverter | Siemens |
| HMI (Human-Machine Interface) | MCGS Touchscreen (1 operable at a time, per floor) |
| Leveling Device | Electric Push Rod (for 5-ton load, interfaces with Hikvision AGV) |
| Safety Light Curtain | Omron |
| In-Car Personnel Sensor | Prevents movement when person is detected near door |
| Signal Tower | 3-Color Light |
| Cable Management | Cable Tray |
| Auxiliary AGV Docking Platform | |
| Platform Type | Hydraulic Scissor Lift |
| Platform Size | 3,000 mm (W) × 2,500 mm (D) |
| Lift Travel | 800 mm |
| Platform Load Capacity | 2,500 kg |
| Platform Height (from ground) | 10 mm (lowered position) |
| Control Integration | Linked to the main lift control cabinet; both interface with AGV system |
| Environmental & Installation | |
| Installation Type | No Pit, Ground Installation |
| Doors per Floor | 3 sets of PVC Rapid Roller Doors (White, 1,900×2,500mm) |
| Enclosure | Full expanded metal mesh enclosure |
| Guardrails | Installed on both sides of the platform (3,000mm L × 1,200mm H) |
| Access Ladder | With protective cage |
Challenges
- Handling of Large, Precision Components: Required stable transfer of large automotive door system components weighing up to 5 tons, with a process that had to be smooth to avoid impact or deformation of precision parts.
- Seamless Integration with AGV Systems: As the “aerial artery” of the smart factory logistics, the equipment had to achieve fully automated, high-precision (±10mm) docking with AGVs (Automated Guided Vehicles) to ensure logistics rhythm matched production pace.
- Space Constraints & High Throughput: The installation site had no pit, requiring ground-level deployment. The system needed high-speed operation (30 m/min) and rapid response to align with the fast-paced rhythm of automotive manufacturing.
- Environmental Safety & System Reliability: In areas with mixed personnel and AGV traffic, multiple physical and electronic safety barriers were essential. Core system components required industrial-grade reliability to withstand the demanding conditions of continuous automotive production.
Workflow
- AGV Delivery & Position Confirmation
An AGV carrying a door assembly or mold pallet, directed by the central dispatch system, automatically travels to the ground-floor lift station. The AGV precisely positions itself on the hydraulic scissor lift platform. Surrounding safety light curtains and position sensors immediately confirm the AGV and load are correctly in place. - Precision Lifting & Platform Leveling Docking
The central control system (PLC) issues the command. The scissor lift platform smoothly raises by 800mm, lifting the AGV and its load until perfectly level (within ±10mm) with the stationary lift car floor on the ground floor. Subsequently, the lift car door and the floor’s PVC rapid roller door open synchronously, creating a seamless passage. - Automatic Transfer & Vertical Transportation
The AGV automatically drives into the lift car interior and precisely unloads the pallet into the designated area. After unloading, the AGV automatically exits and returns to the lift platform. The platform then lowers to its original ground-level height, and the AGV departs to perform other tasks. The lift car door closes, and the car automatically ascends or descends at 30 m/min as commanded, transporting the material precisely to the target floor (e.g., the second-floor assembly line). - Unloading at Target Floor & System Reset
Upon reaching the target floor and achieving high-precision leveling again, the lift car door opens. A receiving AGV on that floor (or the original AGV) can drive into the car, retrieve the material, and deliver it to a specific workstation on the production line. After completing this cross-floor delivery, the system automatically resets to standby mode, ready to execute the next cycle.
Solution
- Large Through-Type Platform: Designed with a 3000mm-wide, through-type platform optimized for standard door-assembly pallets and large molds, allowing unimpeded bidirectional AGV traffic and a rated load capacity of 5000kg.
- Fully Automated AGV Docking Process: Innovatively integrated a 2.5-ton hydraulic scissor lift platform as a “docking bridge.” The fully automated process is: AGV delivers door assembly to the platform → platform lifts to achieve precise leveling with the lift car → AGV drives into the car to unload → AGV exits and the platform lowers. This design perfectly solves the height difference challenge between the ground and the lift car.
- Intelligent Control for Automotive Manufacturing: Driven by Siemens PLC and frequency converters to ensure smooth operation and precise stops at high speeds. Each floor is equipped with an industrial touchscreen for real-time status display. Omron safety light curtains, in-car personnel sensors, and fall-prevention safety gears create a multi-layered safety net compliant with automotive factory standards.
- Robust Industrial Structure: The main structure features welded heavy-duty square tubing and section steel, guided by 20A heavy-duty chains to ensure long-term durability under heavy load impact. Fully enclosed expanded metal mesh and PVC rapid roller doors meet the requirements for area isolation and fast access while ensuring safety.
Details
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1.4.2026 / 4-minute read
External Reciprocating Lift for Cold Storage | 2 tons Automated Pallet Handling System
Overview
Client: A large-scale cold storage and distribution center.
The client mandated a system for reliable 24/7 operation in -25°C conditions, with specific demands:
- High throughput with a 2000kg load capacity.
- Complete automation with conveyor interfaces on both levels.
- Strict temperature integrity during transfers.
- Robust safety features including physical light curtains.
- Specific color scheme (light grey with yellow accents) and component brands (e.g., Dongli motor, Siemens PLC).
Basic Parameters
| Category | Specification |
|---|---|
| Car Specifications | Internal Dimensions: 1900(W) x 1600(D) x 2500(H) mm |
| Rated Load Capacity: 2000 kg | |
| Shaft & Travel | Hoistway Opening: 3200(W) x 2550(D) mm |
| Travel Height: 9800 mm | |
| Number of Stops: 2 Stops / 2 Stations | |
| Performance | Lift Speed: 40 m/min |
| Entry/Exit Direction: Single-side access (3200mm side) | |
| Key Mechanical Components | Lift Motor: 15 KW, DONGLI brand |
| Guiding System: Car Guide Rail T90 / Counterweight Rail TK5A | |
| Safety: Overspeed Governor & Safety Gear, Polyurethane Buffers | |
| Counterweight: 1556 kg | |
| Chain: 16A | |
| Structure & Materials | Main Frame: 120×4 mm Square Tube |
| Car Frame: 160x80x4 mm Rectangular Tube | |
| Top Frame: 200x100x6 mm Rectangular Tube | |
| Integrated Conveyors | Car Conveyor: 1 unit, W1500 x D1600 mm |
| Entry/Exit Conveyors: 2 units, W1500 x D1600 x H520 mm, Speed 15 m/min | |
| Conveyor Roller: 304 Stainless Steel, Ø89mm | |
| Doors & Control | Shaft Doors: PVC Rapid Roll-up Doors (1900x2500mm), 2 sets |
| Control System: Siemens PLC, Manual/Auto modes | |
| HMI: 10-inch Touchscreens (MCGS) at each level | |
| Safety Detection: 200mm height safety light curtains with alarm beacon |
Solution
- Low-Temperature Robustness: Used low-temperature lubricants and suitable structural steel.
- Temperature Lock: Installed high-speed PVC roll-up doors to minimize air exchange.
- Full Automation: Integrated synchronized conveyors for hands-off transfer.
- Comprehensive Safety: Combined light curtains, safety gears, and buffers.
- Custom Compliance: Followed exact color codes and used specified brand components for a seamless fit with client standards.
How It Works
The system operates an automated cycle:
- A pallet is conveyed into the elevator car on the ground floor.
- Rapid doors close. The car lifts to the target floor.
- Doors open, and the car conveyor transfers the pallet out.
- The cycle repeats. PLC-controlled safety systems monitor every step.
Details
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