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Day: 6 December 2023

Greener Farm to Fork Journey

Posted on by David Priestman

5G-technologies could deliver significant carbon savings across food and drink manufacturing from farm to fork, according to new economic modelling. The modelling reinforces the environmental benefits of 5G Standalone (5G SA), particularly for key industries in that are traditionally carbon intensive like manufacturing.

Technologies like Internet of Things (IoT) sensors and tracking systems can transform the way we manage food and drink across the manufacturing supply chain – from its origins on the farm, through to factory production sites and transporting the food on UK roads to our stores. The new modelling reveals that 5G technologies could save the food and drink supply chain 37 million tonnes of CO2 equivalent emissions between 2024 and 2035. That’s the same as removing 78,000 delivery trucks from UK roads.*

However, these efficiencies can only be achieved with the timely rollout of a 5G SA network. That is why, following completion of the proposed joint venture, Vodafone UK and Three UK have committed to investing £11 billion in the first 10 years as a combined business which will help deliver 99% of 5G Standalone population coverage by 2034. This critical infrastructure will deliver a far superior network that will allow us to build towards the UK’s digital future, faster and facilitate the innovations needed to support the UK on its Net Zero journey.

The modelling conducted by WPI Economics for Vodafone reveals the impact that these technologies can have on decarbonising the supply chain.

• In farming, 5G technologies, such as drones and sensors that monitor soil and crop conditions could improve yields and significantly reduce the food waste produced on farms. By 2035, this reduction in food waste can correspond to a total saving of carbon emissions equivalent to 6% of the UK’s greenhouse gas emissions in 2022.
• On the factory line, 5G-enabled manufacturing technologies like remote maintenance systems, which reduce machine downtime, plus IoT tracking systems, which reduce electricity consumption required for cooling and storing goods, could all contribute to an 11% reduction in CO2e emissions in manufacturing by 2035.
• When transporting goods by road, implementing 5G technologies, such as Vehicle-to-Everything to improve the fuel efficiency of Heavy Goods Vehicles (HGV), in the commercial distribution of food and drink could reduce HGV emissions by up to 54 MtCO2e. This equates to more than double the total UK HGV emissions of 2021.

Andrea Dona, Chief Network Officer, Vodafone UK, said: “We’re supporting many customers across the farm to fork supply chain to become more energy efficient through innovative technology like IoT and the Cloud. But we need the proper infrastructure to take it to the next level. 5G Standalone has the potential to transform the UK supply chain, smoothing operations for suppliers and reducing carbon emissions. Vodafone’s proposed combination with Three UK will enable us to invest £11bn over the next decade, reaching over 99% of the UK population with 5G Standalone by 2034 and helping the UK’s agricultural industry decarbonise sooner rather than later.”

A spokesperson from the Road Haulage Association (RHA), said: “The RHA is dedicated to supporting its members to help them sustainably reduce emissions in the road freight and logistics industry. We welcome Vodafone’s newly released research which finds that the implementation of 5G technologies could reduce greenhouse gas emissions in the sector by up to 44%. This year, the RHA launched the Net Zero forum which seeks to collaborate with other leading business voices for sharing best practices, technological advancements, and cutting-edge research related to sustainable transport, and we look forward to continuing to support our members by identifying new technology which will support them to decarbonise.”

In June, Vodafone launched the UK’s first Standalone network, 5G Ultra, creating one of the most technologically advanced network for customers.

Methodology

The estimated figures are based on analysis by WPI Economics using trusted data sources, including data from the Department for Energy Security & Net Zero, Department for Transport and the ONS, as well as academic literature. Overall benefits are calculated based on a Theory of Change flow, which breaks down the total effect into discrete effect channels identified through a literature review. Benefits coming from each channel are estimated and summed together (where applicable). The analysis presents emissions avoided between 2024 and 2035, assuming a staggered implementation of 5G-enabled solutions over time. The estimates are based on official government projections of CO2e emissions by industry, and the projected changes in sources of energy generation.
*Delivery trucks refers to Heavy Goods Vehicles (HGVs).

Greener Farm to Fork Journey

Posted on by David Priestman

5G-technologies could deliver significant carbon savings across food and drink manufacturing from farm to fork, according to new economic modelling. The modelling reinforces the environmental benefits of 5G Standalone (5G SA), particularly for key industries in that are traditionally carbon intensive like manufacturing.

Technologies like Internet of Things (IoT) sensors and tracking systems can transform the way we manage food and drink across the manufacturing supply chain – from its origins on the farm, through to factory production sites and transporting the food on UK roads to our stores. The new modelling reveals that 5G technologies could save the food and drink supply chain 37 million tonnes of CO2 equivalent emissions between 2024 and 2035. That’s the same as removing 78,000 delivery trucks from UK roads.*

However, these efficiencies can only be achieved with the timely rollout of a 5G SA network. That is why, following completion of the proposed joint venture, Vodafone UK and Three UK have committed to investing £11 billion in the first 10 years as a combined business which will help deliver 99% of 5G Standalone population coverage by 2034. This critical infrastructure will deliver a far superior network that will allow us to build towards the UK’s digital future, faster and facilitate the innovations needed to support the UK on its Net Zero journey.

The modelling conducted by WPI Economics for Vodafone reveals the impact that these technologies can have on decarbonising the supply chain.

• In farming, 5G technologies, such as drones and sensors that monitor soil and crop conditions could improve yields and significantly reduce the food waste produced on farms. By 2035, this reduction in food waste can correspond to a total saving of carbon emissions equivalent to 6% of the UK’s greenhouse gas emissions in 2022.
• On the factory line, 5G-enabled manufacturing technologies like remote maintenance systems, which reduce machine downtime, plus IoT tracking systems, which reduce electricity consumption required for cooling and storing goods, could all contribute to an 11% reduction in CO2e emissions in manufacturing by 2035.
• When transporting goods by road, implementing 5G technologies, such as Vehicle-to-Everything to improve the fuel efficiency of Heavy Goods Vehicles (HGV), in the commercial distribution of food and drink could reduce HGV emissions by up to 54 MtCO2e. This equates to more than double the total UK HGV emissions of 2021.

Andrea Dona, Chief Network Officer, Vodafone UK, said: “We’re supporting many customers across the farm to fork supply chain to become more energy efficient through innovative technology like IoT and the Cloud. But we need the proper infrastructure to take it to the next level. 5G Standalone has the potential to transform the UK supply chain, smoothing operations for suppliers and reducing carbon emissions. Vodafone’s proposed combination with Three UK will enable us to invest £11bn over the next decade, reaching over 99% of the UK population with 5G Standalone by 2034 and helping the UK’s agricultural industry decarbonise sooner rather than later.”

A spokesperson from the Road Haulage Association (RHA), said: “The RHA is dedicated to supporting its members to help them sustainably reduce emissions in the road freight and logistics industry. We welcome Vodafone’s newly released research which finds that the implementation of 5G technologies could reduce greenhouse gas emissions in the sector by up to 44%. This year, the RHA launched the Net Zero forum which seeks to collaborate with other leading business voices for sharing best practices, technological advancements, and cutting-edge research related to sustainable transport, and we look forward to continuing to support our members by identifying new technology which will support them to decarbonise.”

In June, Vodafone launched the UK’s first Standalone network, 5G Ultra, creating one of the most technologically advanced network for customers.

Methodology

The estimated figures are based on analysis by WPI Economics using trusted data sources, including data from the Department for Energy Security & Net Zero, Department for Transport and the ONS, as well as academic literature. Overall benefits are calculated based on a Theory of Change flow, which breaks down the total effect into discrete effect channels identified through a literature review. Benefits coming from each channel are estimated and summed together (where applicable). The analysis presents emissions avoided between 2024 and 2035, assuming a staggered implementation of 5G-enabled solutions over time. The estimates are based on official government projections of CO2e emissions by industry, and the projected changes in sources of energy generation.
*Delivery trucks refers to Heavy Goods Vehicles (HGVs).

Shoppers Ditch Sustainability for Bargains

Posted on by David Priestman

Today, Manhattan Associates Inc. (NASDAQ: MANH) announced the findings of a new study on Britain’s sustainable shopping habits in the lead-up to Christmas. At a time when consumer spending is typically high, the fallout from the cost-of-living crisis has revealed that low costs are trumping both sustainability considerations and convenient deliveries and returns, indicating that cost will be paramount for more shoppers this holiday season.

Shopping Sustainably

The survey conducted by YouGov found that 32% of Brits aren’t actively looking for sustainable products or brands when shopping online. This behaviour makes it clear that shoppers are now prioritising their pockets (even more so than shopping with brands who provide convenient deliveries and returns), proving that economic factors play a significant role when it comes to sentiments around sustainability: “The golden quarter and holiday season is well underway but clearly the state of the economy is having an effect on customer behaviour – unfortunately, it looks as if cost is trumping sustainability just now,” commented Craig Summers, Managing Director UKI, MEA & Nordics at Manhattan Associates.

However, outside of the festive season, the data revealed that shoppers are still concerned with sustainability as a broader topic, and that there are growing consumer expectations for businesses to be greener. To help achieve this, customers are willing to make some sacrifices. The research found that:

• Almost two-thirds (64%) of Brits believe it is important for businesses to offer sustainable packaging
• Over half (53%) expect a sustainable product lifecycle, with returned products being actively recycled and reused
• Over half (56%) are also willing to wait to receive multiple parcels in one delivery to cut down on carbon emissions

Retailer Requirements

Brands must find the right balance between providing customers with sustainability and affordability. Redesigning products to take into account sustainability (at the beginning of the design process), ensuring items can be recycled more easily and using more environmentally friendly materials at the outset of production are a vital first step and essential for any brand now facing increased regulatory scrutiny of green claims. On top of this, however, finding ways to decarbonise the supply chains that deliver products will be equally important: rethinking make-or-buy decisions and limiting the need for long-range logistics, setting procurement standards for suppliers and improving visibility across networks will result in a more sustainable retail industry overall.

“This year has been tough for retailers and consumers across the board. From the domestic cost-of-living crisis – magnified by inflation and higher interest rates – to an increasingly fractured macroeconomic environment, 2023 has proved challenging for retailers and consumers alike. While inflation is beginning to ease, the road to recovery will not happen overnight. It perhaps isn’t surprising that customers are prioritising costs above all other aspects right now, especially as we approach Christmas, but hopefully we will see greener shoots of recovery for the economy, and also consumer impetus for sustainability, return in the spring,” concluded Summers.

Shoppers Ditch Sustainability for Bargains

Posted on by Keith McKinley

Today, Manhattan Associates Inc. (NASDAQ: MANH) announced the findings of a new study on Britain’s sustainable shopping habits in the lead-up to Christmas. At a time when consumer spending is typically high, the fallout from the cost-of-living crisis has revealed that low costs are trumping both sustainability considerations and convenient deliveries and returns, indicating that cost will be paramount for more shoppers this holiday season.

Shopping Sustainably

The survey conducted by YouGov found that 32% of Brits aren’t actively looking for sustainable products or brands when shopping online. This behaviour makes it clear that shoppers are now prioritising their pockets (even more so than shopping with brands who provide convenient deliveries and returns), proving that economic factors play a significant role when it comes to sentiments around sustainability: “The golden quarter and holiday season is well underway but clearly the state of the economy is having an effect on customer behaviour – unfortunately, it looks as if cost is trumping sustainability just now,” commented Craig Summers, Managing Director UKI, MEA & Nordics at Manhattan Associates.

However, outside of the festive season, the data revealed that shoppers are still concerned with sustainability as a broader topic, and that there are growing consumer expectations for businesses to be greener. To help achieve this, customers are willing to make some sacrifices. The research found that:

• Almost two-thirds (64%) of Brits believe it is important for businesses to offer sustainable packaging
• Over half (53%) expect a sustainable product lifecycle, with returned products being actively recycled and reused
• Over half (56%) are also willing to wait to receive multiple parcels in one delivery to cut down on carbon emissions

Retailer Requirements

Brands must find the right balance between providing customers with sustainability and affordability. Redesigning products to take into account sustainability (at the beginning of the design process), ensuring items can be recycled more easily and using more environmentally friendly materials at the outset of production are a vital first step and essential for any brand now facing increased regulatory scrutiny of green claims. On top of this, however, finding ways to decarbonise the supply chains that deliver products will be equally important: rethinking make-or-buy decisions and limiting the need for long-range logistics, setting procurement standards for suppliers and improving visibility across networks will result in a more sustainable retail industry overall.

“This year has been tough for retailers and consumers across the board. From the domestic cost-of-living crisis – magnified by inflation and higher interest rates – to an increasingly fractured macroeconomic environment, 2023 has proved challenging for retailers and consumers alike. While inflation is beginning to ease, the road to recovery will not happen overnight. It perhaps isn’t surprising that customers are prioritising costs above all other aspects right now, especially as we approach Christmas, but hopefully we will see greener shoots of recovery for the economy, and also consumer impetus for sustainability, return in the spring,” concluded Summers.

Proactive Monitoring and Maintenance

Posted on by Keith McKinley

In times of increasing competitive pressures there is a need for optimal productivity, it is essential for companies to guarantee the permanent operational readiness of their automated storage and retrieval systems in the warehouse.

“Kardex customers don’t just seek the perfect solution, they crave the assurance that it’s smooth sailing all the way. Because let’s face it, in the fast-paced world of logistics, even if a hiccup occurs, business must go on. True success lies in seamlessly integrating business and process continuity into every solution we offer,” says Michael Tyler, LCS Director at Kardex.

Proactive Monitoring and Maintenance with Remote Support from Kardex is a digital solution that helps companies ensure the optimal productivity and operational readiness of their automated storage and retrieval systems in the warehouse. It includes two main features: Remote Assistance and Remote Analytics.

Remote Assistance allows operators to continuously monitor their Kardex Remstar automated storage and retrieval systems. They can request technical support directly from the storage unit, providing all the relevant information to the support team. The support team can then assist in solving any problems remotely. If the system is down, it automatically reports the issue, ensuring quick reaction times and efficient assistance. Simple user errors can be fixed remotely, and if a part is needed for repair, the remote service technician is aware in advance, eliminating long wait times for spare parts and reducing system downtime.

Remote Analytics provides users with access to all unit data on an online service portal. This allows them to view the data of their networked systems from anywhere via a web browser. They can use the live overview to verify the status of the units at any time. The data includes information on the status of the machines, system performance metrics such as the number of cycles, and any potential error history. By tracking the number of cycles, users can determine when system maintenance should be performed based on actual usage, rather than relying on factory standards or averages.

Monitoring and Maintenance
Monitoring and Maintenance

Kardex ensures the security of sensitive data by implementing measures such as two-factor authentication, secure storage of data, and data transmission channels protected by state-of-the-art firewalls. Remote Support is an important part of Kardex’s service offering to guarantee maximum success in storage logistics operations. It helps customers maximise the efficiency of their units and ensures business continuity by minimising system downtime and optimising maintenance schedules.

See How Kardex Remote Support Works: Video Animation

Autonomous Outdoor Forklift Operation

Posted on by David Priestman

Intralogistics specialist Linde Material Handling and the Aschaffenburg University of Applied Sciences (UAS) presented the results of the research project “KAnIS – Cooperative Autonomous Intralogistics Systems” with live demonstrations on the test site at the Linde plant in Aschaffenburg on December 5, 2023. In several subprojects, solutions were developed for the demanding applications of autonomous counterbalanced forklifts, which transport loads both indoors and outdoors. One focus was on the cooperative behaviour of these vehicles that exchange information in real time via a 5G network and an edge server and can warn each other of obstacles. The project, which ran for almost four years, was funded with approximately 2.8 million euros as part of the Free State of Bavaria’s ‘Information and Communication Technology’ R&D program.

“Autonomous vehicles will gradually take over more and more transport tasks,” asserts Stefan Prokosch, initiator of the KAnIS project at Linde MH. As a technology leader in the industry, the intralogistics specialist wants to make the benefits of autonomous vehicles available to customers who use counterbalanced forklifts to transport goods or load and unload heavy trucks. “However, the requirements for forklifts operating in outdoor areas are much higher than those for purely indoor vehicles. These include the ability to operate on inclines and gradients, the presence of a significantly higher volume of people and traffic and different weather influences and temperature conditions that need to be taken into account,” Prokosch explains. “Thanks to the joint research work with Aschaffenburg UAS, we have been able to develop viable solutions for these complex requirements. Once the project is completed, these findings will form an essential basis for further development projects.”

The overall goal of the project was to investigate how the cooperative behaviour of networked, autonomous vehicles can improve operational reliability and handling performance. To solve this broad task, several subprojects were formed to address vehicle location, regulation and control as well as forklift cooperation, load carrier recognition, the impact of weather influences, predictive maintenance, route optimization and automatic load management.

“For the university, the KAnIS project was a very complex, interdisciplinary research project. Ten professors and numerous research assistants and students were involved,” summarized Prof. Dr. Hans-Georg Stark, Project Manager KAnIS, Faculty of Engineering at Aschaffenburg UAS, during the event. “Both project partners have benefited greatly from the intensive exchange between Aschaffenburg UAS’s scientific research activities and Linde MH’s many years of expertise in vehicle development.”

Practice-oriented test scenarios under realistic conditions

Four Linde E20, E25 and E30 electric counterbalanced trucks with a load capacity of 2.0 to 3.0 tons were automated and equipped with electrohydraulic steering (Linde Steer Control), the Linde Safety Pilot assistance system with electronic load diagram and an integrated fork positioner. “The practical implementation of the research results was an important aspect for both Linde MH and Aschaffenburg UAS,” emphasized Mark Hanke, a Head of Department in Pre-Development at Linde MH. Starting next year, the vehicles are to be further developed and tested so that they can perform four specific material handling tasks in the future. These include the transport of wire mesh crates and of pallets containing batteries, and the relocation of vehicle frames and overhead guards, which have to be transported on special load carriers from pre-assembly to the main assembly lines.

The first two applications are purely outdoor operations, while the other two require the trucks to travel both inside and between the halls. Gradients of 8 percent have to be overcome, and there are also other AGVs and manually operated vehicles in the halls. To ensure that the four KAnIS forklifts can reliably pick up the pallets, wire mesh crates and metal frames even if they are not precisely aligned with the floor, they are equipped with a mobile camera mounted between the forks. It measures the pockets of the load carrier so that the forks can be positioned correctly via the side shift. The designs of the vehicle frame, battery door and counterweight were adapted as well. “Our goal was to integrate the safety scanners, cameras and sensors as much as possible into the vehicle contour so that the truck’s dimensions remain as close as possible to the standard version,” says Hanke. Indoors, the vehicles locate themselves via laser scanners, outdoors, they use differential GPS (Global Positioning System), a method of increasing the accuracy of GPS. In addition, they feature additional local sensors for the switch from indoor to outdoor areas. Unlike their manually operated counterparts, the automated forklifts always travel in reverse on their defined routes to prevent the load from slipping off the forks in the event of an emergency stop.

Real-time communication with trucks and infrastructure

A particular focus of the research project was on the automated forklifts’ perception of their surroundings in order to ensure their reliable interaction with other road users. For this purpose, the vehicles are equipped with 3D scanners and HD cameras in addition to the sensors of the personal protection system. The camera data forms the basis for detecting and classifying objects with the help of AI algorithms and then locating them in order to adjust the vehicle’s speed and slow it down to a standstill. But that’s not all. Another key issue focused on critical situations that arise when people are in concealed areas that cannot be detected by the forklift’s sensors and approach the vehicle’s path of travel. This is where cooperation between the forklift trucks comes into play, because if another forklift is in the vicinity, it can provide the relevant information. However, this requires real-time transmission of the perception data. To achieve these low latencies, Linde has set up a private 5G network at the Aschaffenburg plant. The perception data is transmitted from the forklifts to an edge server, which uses the locally detected objects to create a global list of all detected objects and sends it back to the forklifts.

The test was conducted using a crash-test dummy that suddenly emerges from behind a wall and runs into the forklift’s path. Without cooperative behaviour, the automated forklift truck cannot stop in time and runs into the dummy. However, if it receives real-time information from a nearby forklift, it can anticipate the dangerous situation in advance and brake in time. Since it is not always possible to assume that a second forklift is nearby, eight stationary 3D laser scanners were installed at intersections and gateways along the routes that the KAnIS forklift trucks will travel in the future. The local object lists of the stationary laser scanners are also merged on the edge server and the information is made available to all vehicles.

“Fast wireless networks are the prerequisite for autonomous forklifts to be able to act cooperatively in outdoor areas and react to unforeseen traffic situations in real time,” emphasized Prof. Dr. Klaus Zindler, Vice President for Research and Transfer at Aschaffenburg UAS, at the event. “Our goal is to develop general standards and algorithms using AI methods, which can then be flexibly applied to different vehicles and applications and continue to learn.”

Cleaning system for sensors, battery charging by robot

Another work package looked at how to clean the near-ground optical sensors when they become dirty from water splashes in the rain or wet road surfaces. This is critical because if reliable object detection is no longer possible, the operator protection system will automatically bring the truck safely to a stop. To prevent this, the project team developed a cleaning system that uses compressed air to blow off any dirty water droplets that may have collected on the laser scanners.

Another project team investigated possible solutions for autonomous charging of the forklift batteries. The result was in favour of an AI-based robot that connects the charging plug to the forklift’s charging socket. The rear of the truck was modified accordingly and an automatically operated charging flap was added to protect the charging socket from dirt and splash water.

Autonomous Outdoor Forklift Operation

Posted on by David Priestman

Intralogistics specialist Linde Material Handling and the Aschaffenburg University of Applied Sciences (UAS) presented the results of the research project “KAnIS – Cooperative Autonomous Intralogistics Systems” with live demonstrations on the test site at the Linde plant in Aschaffenburg on December 5, 2023. In several subprojects, solutions were developed for the demanding applications of autonomous counterbalanced forklifts, which transport loads both indoors and outdoors. One focus was on the cooperative behaviour of these vehicles that exchange information in real time via a 5G network and an edge server and can warn each other of obstacles. The project, which ran for almost four years, was funded with approximately 2.8 million euros as part of the Free State of Bavaria’s ‘Information and Communication Technology’ R&D program.

“Autonomous vehicles will gradually take over more and more transport tasks,” asserts Stefan Prokosch, initiator of the KAnIS project at Linde MH. As a technology leader in the industry, the intralogistics specialist wants to make the benefits of autonomous vehicles available to customers who use counterbalanced forklifts to transport goods or load and unload heavy trucks. “However, the requirements for forklifts operating in outdoor areas are much higher than those for purely indoor vehicles. These include the ability to operate on inclines and gradients, the presence of a significantly higher volume of people and traffic and different weather influences and temperature conditions that need to be taken into account,” Prokosch explains. “Thanks to the joint research work with Aschaffenburg UAS, we have been able to develop viable solutions for these complex requirements. Once the project is completed, these findings will form an essential basis for further development projects.”

The overall goal of the project was to investigate how the cooperative behaviour of networked, autonomous vehicles can improve operational reliability and handling performance. To solve this broad task, several subprojects were formed to address vehicle location, regulation and control as well as forklift cooperation, load carrier recognition, the impact of weather influences, predictive maintenance, route optimization and automatic load management.

“For the university, the KAnIS project was a very complex, interdisciplinary research project. Ten professors and numerous research assistants and students were involved,” summarized Prof. Dr. Hans-Georg Stark, Project Manager KAnIS, Faculty of Engineering at Aschaffenburg UAS, during the event. “Both project partners have benefited greatly from the intensive exchange between Aschaffenburg UAS’s scientific research activities and Linde MH’s many years of expertise in vehicle development.”

Practice-oriented test scenarios under realistic conditions

Four Linde E20, E25 and E30 electric counterbalanced trucks with a load capacity of 2.0 to 3.0 tons were automated and equipped with electrohydraulic steering (Linde Steer Control), the Linde Safety Pilot assistance system with electronic load diagram and an integrated fork positioner. “The practical implementation of the research results was an important aspect for both Linde MH and Aschaffenburg UAS,” emphasized Mark Hanke, a Head of Department in Pre-Development at Linde MH. Starting next year, the vehicles are to be further developed and tested so that they can perform four specific material handling tasks in the future. These include the transport of wire mesh crates and of pallets containing batteries, and the relocation of vehicle frames and overhead guards, which have to be transported on special load carriers from pre-assembly to the main assembly lines.

The first two applications are purely outdoor operations, while the other two require the trucks to travel both inside and between the halls. Gradients of 8 percent have to be overcome, and there are also other AGVs and manually operated vehicles in the halls. To ensure that the four KAnIS forklifts can reliably pick up the pallets, wire mesh crates and metal frames even if they are not precisely aligned with the floor, they are equipped with a mobile camera mounted between the forks. It measures the pockets of the load carrier so that the forks can be positioned correctly via the side shift. The designs of the vehicle frame, battery door and counterweight were adapted as well. “Our goal was to integrate the safety scanners, cameras and sensors as much as possible into the vehicle contour so that the truck’s dimensions remain as close as possible to the standard version,” says Hanke. Indoors, the vehicles locate themselves via laser scanners, outdoors, they use differential GPS (Global Positioning System), a method of increasing the accuracy of GPS. In addition, they feature additional local sensors for the switch from indoor to outdoor areas. Unlike their manually operated counterparts, the automated forklifts always travel in reverse on their defined routes to prevent the load from slipping off the forks in the event of an emergency stop.

Real-time communication with trucks and infrastructure

A particular focus of the research project was on the automated forklifts’ perception of their surroundings in order to ensure their reliable interaction with other road users. For this purpose, the vehicles are equipped with 3D scanners and HD cameras in addition to the sensors of the personal protection system. The camera data forms the basis for detecting and classifying objects with the help of AI algorithms and then locating them in order to adjust the vehicle’s speed and slow it down to a standstill. But that’s not all. Another key issue focused on critical situations that arise when people are in concealed areas that cannot be detected by the forklift’s sensors and approach the vehicle’s path of travel. This is where cooperation between the forklift trucks comes into play, because if another forklift is in the vicinity, it can provide the relevant information. However, this requires real-time transmission of the perception data. To achieve these low latencies, Linde has set up a private 5G network at the Aschaffenburg plant. The perception data is transmitted from the forklifts to an edge server, which uses the locally detected objects to create a global list of all detected objects and sends it back to the forklifts.

The test was conducted using a crash-test dummy that suddenly emerges from behind a wall and runs into the forklift’s path. Without cooperative behaviour, the automated forklift truck cannot stop in time and runs into the dummy. However, if it receives real-time information from a nearby forklift, it can anticipate the dangerous situation in advance and brake in time. Since it is not always possible to assume that a second forklift is nearby, eight stationary 3D laser scanners were installed at intersections and gateways along the routes that the KAnIS forklift trucks will travel in the future. The local object lists of the stationary laser scanners are also merged on the edge server and the information is made available to all vehicles.

“Fast wireless networks are the prerequisite for autonomous forklifts to be able to act cooperatively in outdoor areas and react to unforeseen traffic situations in real time,” emphasized Prof. Dr. Klaus Zindler, Vice President for Research and Transfer at Aschaffenburg UAS, at the event. “Our goal is to develop general standards and algorithms using AI methods, which can then be flexibly applied to different vehicles and applications and continue to learn.”

Cleaning system for sensors, battery charging by robot

Another work package looked at how to clean the near-ground optical sensors when they become dirty from water splashes in the rain or wet road surfaces. This is critical because if reliable object detection is no longer possible, the operator protection system will automatically bring the truck safely to a stop. To prevent this, the project team developed a cleaning system that uses compressed air to blow off any dirty water droplets that may have collected on the laser scanners.

Another project team investigated possible solutions for autonomous charging of the forklift batteries. The result was in favour of an AI-based robot that connects the charging plug to the forklift’s charging socket. The rear of the truck was modified accordingly and an automatically operated charging flap was added to protect the charging socket from dirt and splash water.

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