Project Background

Since entering China in 1994, a globally renowned service brand has established branch offices in Guangzhou, Beijing, Shanghai, Shenzhen, and other cities. To accelerate goods transshipment, the company constructed a large regional warehouse in Kunshan, Jiangsu, to enhance business support capabilities. This project, serving as the foundation of the warehouse's intelligent infrastructure, aims to build a green, efficient, and intelligent environment through the integration of next-generation low-voltage systems.

Construction Goals
  • Improve Efficiency: Reduce manual operations and shorten inbound/outbound processing time through automation.
  • Reduce Costs: Optimize inventory management to minimize redundancy and waste.
  • Enhance Accuracy: Leverage AI and sensor technologies for precise inventory control.
  • Ensure Safety & Compliance: Real-time monitoring of warehouse environment and operations.
  • Support Scalability: Prepare for future business growth and technology upgrades.

Solution Overview

The project includes solutions based on Cisco Networking, Bosch Security Systems, and Huawei Modular Data Center Infrastructure.

Cisco Network Design
Three-Tier Network Architecture
  • Core Layer: 2 × Cisco Catalyst 9500-48Y4C switches interconnected via 40G fiber, with HSRP for gateway redundancy
  • Distribution Layer: 2 × C9300-48UXM stacked switches per zone, 10G uplinks to the core, SD-Access enabled
  • Access Layer: Wired, Industrial-grade PoE++ switch (C9200L-48P-4G) powers cameras and APs (UPOE 60W support). Wireless, Wi-Fi 6 APs (C9117AXI) for dense coverage; Cisco 5G IR1101 routers in AGV operation areas for low-latency connectivity
Wireless Coverage Plan
  • 2.4GHz: Channels 1/6/11 with speed limits for low-priority devices (e.g., sensors)
  • 5GHz: 80MHz bandwidth prioritized for AGV/AR devices (DFS enabled)
  • AP Density: 1 AP per 800–1000㎡; C9120AXI with directional antennas used in shelving areas
  • FlexConnect Mode: Local traffic breakout for video streams, reducing controller load
Industrial Protocol Support
  • TSN (Time-Sensitive Networking): IEEE 802.1Qbv enabled for PROFINET RT traffic prioritization
  • IoT Integration: Cisco IE3400 industrial switches connect to PLCs/RFID readers with OPC UA over TSN support

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Bosch Security System Design
Video Surveillance

Front-end Devices:

  • Outdoor/Dock Areas: Bosch DINION IP 8000 MR (4K, starlight, IP66)
  • Shelving/Passageways: Bosch FLEXIDOME IP 7000 panoramic cameras (180°/360° view, people counting)
  • Cold Storage: Bosch AUTODOME IP 5000 low-temperature cameras (operating at -40°C, anti-fog)

Smart Analytics (IVA)

  • Fire/smoke detection, fall detection, object abandonment/movement alerts
  • AGV path deviation alerts to prevent collisions
Access Control

Control Core: Bosch ACCESS EC controller (supports 5,000 doors, TCP/IP redundant communication).

Identification Methods:

  • Controller: Bosch ACCESS EC (supports up to 5,000 doors, TCP/IP redundant communication)
  • Authentication: High-security zones: Bosch IDP facial recognition terminals (liveness detection, 1s recognition) General areas: IC card + fingerprint

Emergency Protocols:

  • Fire-triggered automatic door release
  • Forced entry triggers alarm and camera snapshot

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Huawei Modular Data Center Design
Power Supply System
  • Dual power input (380V), ATS automatic switching (<10ms failover)
  • Modular UPS: Huawei UPS5000-E with N+1 redundancy, lithium battery support (60% smaller than lead-acid)
  • Smart PDUs: Per-rack power/current monitoring with threshold alerts
Cooling System
  • In-row precision cooling (NetCol5000-A series) close to heat sources (COP ≥ 4.0)
  • Cold aisle containment with tempered glass doors and overhead panels (improves cooling efficiency by 40%)
  • AI-powered cooling adjustment (iManager predicts load and adjusts fan speeds)

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Key Benefits

  • Significant improvement in warehouse transportation efficiency
  • High level of automation in goods sorting
  • Advanced digitalization with reduced IT O&M burden
  • Fully digitalized facility management

Customer Pain Points

  • Network Bottlenecks: Low-bandwidth legacy networks cannot support the increasing data exchange from IoT devices. Large warehouse areas and metal shelving cause severe Wi-Fi signal attenuation and unstable AGV/AMR communications.
  • Security & Surveillance Gaps: Traditional passive surveillance lacks proactive AI detection. Access control and surveillance systems are siloed, creating blind spots and poor system integration.
  • Low System Integration: Incompatible protocols among different vendor equipment (e.g., Hikvision + Siemens PLC) lead to data silos, poor interconnectivity, and management inefficiencies.

Customer Gains

  • Operational Efficiency: AGVs and automation reduce manual handling and boost order processing. Nighttime unmanned operations extend productive hours. Wireless AP deployment enhances device mobility.
  • Cost Reduction: Automated sorting and inventory reduce labor costs. Remote surveillance replaces manual patrols. Digital workflows reduce consumables like printouts and labels.
  • Enhanced Security & Compliance: AI cameras detect fire, intrusion, and other events in seconds (vs. minutes). Full traceability of goods throughout the warehouse lifecycle ensures compliance.