Until recently, automation and robotization only concerned large warehouses of multinational companies. Smaller logistics operations were mostly satisfied with automation in the form of conveyors or automatic stackers. However, warehouse workers still have to perform a lot of manual handling of goods. This can be taken over by a robotic colleague. The demands on warehouse logistics continue to grow. Many companies are now beginning to address their strategy for further development—how to increase shipping capacity, how to cope with the growing range of products and number of shipments. On the other hand, there is a shortage of warehouse workers. The deployment of robots and industrial automation, ideally a combination of both, presents a new challenge.
No more getting lost in the warehouse – robotic pallet handling
For pallet handling, we now offer myFABER® AGV assistants with load capacities of 600, 1,000, and 1,500 kg, which can be navigated in the warehouse using QR codes affixed to the floor. We define virtual routes for the robots and control their movement between individual locations. The advantage of this solution is definitely the greater speed of the robots, but also the lower price.
One disadvantage is that handling pallets requires a special design solution for lifting so that the robot can drive under the pallet. We have taken this into account and have already come up with several design solutions. It is also necessary to create special zones or routes where only robots are allowed to operate. Although the robot is equipped with high-quality, accurate sensors for detecting obstacles in front and behind, if the communication route is disrupted by human operators or other objects, it must wait for it to be cleared.
Wherever robots prove unsuitable, we offer a solution that uses SLAM technology and spatial orientation for navigation. The robot’s paths are entered into a digital map, and the robot moves around using autonomous navigation and laser sensors. The latest models can handle even very narrow aisles because they use a set of motors and wheels and can move in straight lines and perpendiculars.
Joining forces – integrating robots into warehouse processes
On the myFABER® WES/WCS platform, we are able to integrate robots from different technologies and manufacturers. In high-bay pallet warehouses, we can integrate autonomous forklift robots that perform two-way vertical pallet handling between the relevant pallet location and the ground floor. At the bottom, “small” low robots with a lift of only a few centimeters handle the pallets horizontally. Thanks to their combination, we are able to increase the speed and number of pallets handled per hour and also significantly reduce the price of the entire solution.
Here is Robot´s – a fully autonomous pallet warehouse
Another opportunity for innovation in pallet handling is the deployment of a fully autonomous pallet warehouse. The shuttle robot moves in 3D and is capable of horizontal pallet handling in all directions. This includes both movement in the relevant aisles and entry into specific logistics positions. The shuttle truck also lifts and lowers pallets and is able to enter an elevator, which provides separate vertical movement, and work on another floor. By installing multiple such robots and elevators, pallet movement in the corresponding pallet warehouse structure can be fully automated, for example by adding an input and output conveyor for pallets.
All movement in the unified storage space cell is thus automated. This solution also allows for the combination of elements of so-called stacking storage, where individual pallets are stored directly behind each other on a specific floor and aisle without an additional aisle. This makes it possible to achieve even higher storage density per cubic meter if we do not need to have every stored pallet quickly accessible. All of this can be combined both at the floor level and in individual aisles. This allows us to achieve high density and the required performance of the entire system.
The design of the automated warehouse is based on the customer’s requirements for the number of pallet positions and their expectations for maximum hourly and daily pallet throughput. The solution allows for maximum use of the warehouse height and gradual expansion in case of future development or increased performance requirements.
Piece by piece – robotization of piece assortment
Warehouse logistics is not just about storing and shipping pallets. Many goods and products need to be stored in smaller packages or pieces. In traditional storage and shipping, a warehouse worker walks through the warehouse and picks individual items in the required quantities. Modern technology is changing this concept by using robotic systems to bring the assortment to the warehouse worker. Mobile racks or robots are used to handle cartons or plastic crates, such as KLT crates. Thanks to this concept, storage space can be densified and storage performance increased by hundreds of percent.
Unity in diversity – integrating robotization and automation into intralogistics
As we have been able to verify in recent months through completed projects, the key factor is the ability to integrate individual robotic technologies with the requirements of logistics operations, which are now concentrated and processed in modern ERP systems or advanced WMS. However, it is not just a matter of integrating data and software, but also of supplementing robotic technologies with elements that turn them into functional and efficient units. Such elements include traditional belt conveyors, crossings, and separation components, as well as packaging lines and machines for the production or assembly of packaging. Where human operators are involved in the processes, technologies using light, such as pick-to-light, laser pointers, or lighting of shipping positions, have proven to facilitate work. Other benefits include barcode readers integrated into gloves or worn on the finger, and voice control technology. Thanks to significant investments in the past, KVADOS is well prepared to integrate these technologies into comprehensive solutions.
