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Tag: Materials Handling

Innovative drive concepts from Nord

Posted on by David Priestman

E-commerce is booming and so is warehouse automation. Flexible warehouse systems are also in demand in large grocery chain warehouses, and require environmentally friendly, sustainable and intelligent drive concepts. Drive specialist is highly familiar with the industry’s requirements and offers a variety of dynamic drive solutions which are suited for various applications and requirements in warehouse logistics.

Nord offers customised drive solutions for warehouse logistics for an optimum compromise between investment, operating and maintenance costs. With motor efficiency class IE4 and system efficiency class IES2, the drive units achieve excellent efficiencies – especially in the partial load and speed range. The latest generation IE5 permanent magnet synchronous motors achieve an even higher energy efficiency and significantly reduces the energy consumption. The constant torque over a wide speed range allows for a targeted version reduction. This minimises administrative expenses, and enables leaner manufacturing, logistics, storage and service processes.

NORDAC ON frequency inverter

The decentralised NORDAC ON frequency inverter has been developed for horizontal conveyor technology requirements in warehousing, and the NORDAC ON+ variant for interaction with the new IE5+ synchronous motor. It is characterised by an integrated Ethernet interface, its ease of maintenance through complete pluggability and an extremely compact design – providing an economical and intelligent plug-and-play solution for IIoT environments.

The compact, smart frequency inverter for decentralised use can be mounted directly on the geared motor. It covers lower power ranges of up to 2.2kW and has an energy-saving function in the partial load range. The integrated Ethernet interface reduces the effort for integration into modern automation systems: Whether for ProfiNet, EtherNet/IP or EtherCAT, the required protocol can be easily set via parameters.

Efficiency in conveyor technology

The NORDAC FLEX SK 205E series is also ideally suited for applications in warehouse logistics. The compact, decentralised and energy-efficient frequency inverter offers a wide power range of up to 22 kW and enables energy savings over the entire load range. The inverter can be used to control standard asynchronous motors, high-efficiency synchronous motors and brake motors. It can be installed close to the drive in the field or motor-mounted.

Power and data cable connections are available as plug-in versions. The decentralised system enables short motor and encoder cables as well as short supply cables to sensors. Encoder feedback can be included, for example, for position-controlled transport systems. The large overload capacity of the NORDAC FLEX SK 205E makes dynamic movements with short start and stop times or cyclic operation possible. The integrated POSICON control enables high precision in synchronous and positioning applications.

Overall, Nord convinces with a wide range of products in the field of warehousing, including both established basics and high-efficiency products. Users benefit from tailored and reliable drive solutions which ensure an optimum system availability. The Nord modular drive system thus enables an optimum compromise between investment, operating and maintenance costs.

 

 

New Yale forklifts offer bespoke options

Posted on by David Priestman

The one-size-fits-all lift truck solution of yesterday won’t cut it any longer, says Yale. To meet today’s challenges head on, customers need a truck that is configured to the unique demands of their applications. The Yale Series N will create a new level of excellence in lift truck solutions; the performance, ergonomics and configurability will give customers everything they need – raising the bar for success.

The Series N moves away from the defined categories of basic, standard, and premium lift trucks to a completely new customer experience that enables them to define their own truck specification.

Phil Mean, Product Strategy Manager at Yale Europe Materials Handling, said: “The introduction of the Series N is a pivotal moment for Yale. In a time of forklift operator shortages and rising costs, it’s important for operations to have equipment that matches their needs. The Series N challenges customers to reject the status quo, and set their own standard. Even in extreme applications, the trucks can be configured to suit the customers’ needs – all while offering operator comfort to promote high levels of productivity.”

The first truck available in the range is the GDP/GLP 2.0-3.5N, with more electric and ICE trucks due to be released in the future.

Operator-centric design

Yale says the Series N is designed to the needs of the operators and the challenges of the individual operation – rather than customers using a truck with functionalities they simply don’t need or use. The value of the trucks goes beyond moving goods from A to B; the Series N can reduce labour challenges through excellent ergonomics to assist with staff retention.

Boasting an easy three-point access, a large grab handle and generous foot space reduces strain and twisting as the operator gets in or out of the cab. A flip-up armrest provides an unobstructed route when raised, and additional comfort when down.

“We all know we work best with the right tools and supportive surroundings, so we have designed the operator compartment to be spacious, with excellent head and shoulder clearance and a full suspension seat. Even during a long shift, operators can rely on the Series N to provide comfortable working conditions,” added Mean.

All-round visibility

The trucks have a wide mast window, offering excellent forward visibility while handling loads or travelling. A fork laser level line option allows the operator to quickly see where the fork tips will enter a pallet load – great for low light environments – while a clear glass roof option allows unobstructed upward view, helping the operator to pick and place loads at height precisely.

Combined with industry-exclusive technology, the Yale Series N range supports peak performance, confidence, and productivity. A standard, full-colour touch screen display offers quick, easy access to vital truck information.

Other optional operator assist systems on the new lift trucks include a reverse driving camera and rear-view display, a highly configurable suite of spotlight and pedestrian awareness light options and mounting positions, and integrated proximity and object detection systems.

“Being able to work with confidence is key to achieving productivity goals and keeping operations moving,” continued Mean. “As well as high visibility and excellent ergonomics, the Yale Series N lift trucks feature rapid acceleration and fast lift/lower speeds – helping to shave off crucial seconds in every cycle.”

Efficient and dependable

With increasingly demanding productivity targets pushing any operations to run two or even three shifts, logistics operators need to set a new standard for high uptime and low cost of ownership.

Harsh duty cycles and challenging environments can threaten uptime. The Yale Series N range has been designed to deliver, shift after shift.

The lift trucks boast low fuel consumption, enabling them to do more work with less fuel. Reliable and robust components reduce the amount of maintenance required, keeping the truck moving for as long as possible and reducing downtime.

“There are so many more benefits and features of our new range to be discovered, so we encourage logistics operators to get in touch to find out more,” concluded Mean. “Our dealer and sales teams will work directly with our customers to understand their specific needs and help them define exactly what they need from a Series N truck.

“It is a ground-breaking offering, and it will transform the way Yale creates solutions for our customers. We have always said people are at the heart of our products, and in allowing our customers to create a bespoke lift truck for their application, the Series N epitomises this completely.”

IFOY FINALIST FOCUS: IKEA Project Flat Pack Picking by SSI Schäfer

Posted on by David Priestman

Next up in our series examining each of the IFOY Award nominated finalists ahead of the winners announcement on 30th June at BMW World, we look at the first of two solutions in the Integrated Warehouse Solution category –  IKEA Project Flat Pack Picking by SSI Schäfer.

IFOY category: Integrated Warehouse Solution

Flat pack picking lets SSI Schäfer offer a truly unique, automated and turnkey system solution from a single source, providing safe, efficient and volume-optimised palletising of heavy and bulky items typical for the furniture sector. The picking module with gantry robots facilitates the efficient handling of an especially heterogeneous range of items, reduces the burden of non-ergonomic tasks on employees and stands out with its high degree of scalability.

Customer: Inter IKEA Group

Realisation Phase:
From: 2019-08-08
To: 2021-04-19

Description

The multinational furniture company IKEA has successfully implemented a fully automated order picking system for handling bulky and heavy items at its customer order distribution centre in Dortmund, Germany, together with its long-term intralogistics partner SSI Schäfer , as part of its efforts to create a more ergonomic and healthier working environment for its employees. The heart of the system is the flat pack picking solution with an intelligent gantry robot picking system. The turnkey, scalable as well as high performance system is flexible in its handling, suitable for a variety of heavy, bulky items and automatically generates optimal pack patterns for the order pallets. Modern robotics applications reduce the workload of the workforce in handling goods of this kind.

Who hasn’t heard of them, those classic products MALM, IVAR or PAX? IKEA opened its first furniture store in Germany way back in 1974. Since then, the Swedish furniture chain has been delighting customers with a wide assortment of products in Scandinavian design. This ongoing successful trajectory has continued even during the pandemic: For the 2020 fiscal year, IKEA Germany reported sales revenue of €5.325 billion in store-based retail. Despite the COVID-19 pandemic, the home furnishings group generated growth of 0.9%. In the e-commerce segment, sales revenue increased by 74.3% to €861 million. The online share almost doubled as compared to the previous year and is now reported at 16.2%. The growing trend in favour of online furniture purchases is compensating for the downturn in furniture stores caused by the COVID-19 crisis.

Providing a consistent response to economic and social challenges
While IKEA is the undisputed number one in furniture retailing in Germany, the industry is still engaged in an intense price war. This makes it important to continuously adapt cost structures and processes, including logistics, to the dynamic market situation to ensure that IKEA can offer its customers an appealing, competitive range of goods. IKEA is handling this challenge with great success: “Steadily increasing efficiency while at the same time increasing throughput is a constant incentive for us,” says Julien Weiß, Intralogistics Development, Inter IKEA Group. “With this in mind, and primarily in order to reduce the manual workload of our employees, IKEA is increasingly investing in the automation of its intralogistics processes.” This is how the furniture group is responding to the persistent cost pressure while also focusing on the health of its staff. Conventional manual picking of heavy and bulky parts, such as chests of drawers or cabinets, can put a strain on the musculoskeletal system. Plus, hiring the right warehouse staff for positions that involve physical labour is tough.

Concept study as the initial spark for the pilot project
IKEA Intralogistics acts, for all intents and purposes, as an in-house consultant and also ensures continuous improvement of the processes at its customer order distribution centre in Dortmund. In 2017, management there began to consider the deployment of robots in the area of order picking in collaboration with SSI Schaefer, a project partner they had trusted for many years. This approach was part of a concept study, also developed jointly, to optimise logistics in the handling of customer order business. “Both the heterogeneous range of articles and the large proportion of heavy and bulky items were particularly challenging here,” says Tim Langenbach, Director Business Development Retail & Wholesale, SSI Schäfer . “As a full-range supplier in the field of intralogistics, we were able to work in close coordination to identify a suitable solution to this problem.” As part of a test installation and subsequent simulation, the flat pack picking system, which is being used for the first time in Dortmund, was determined to be the ideal solution after a “proof of concept.” The predefined customer requirements were met with an integrated logistics solution from a single source, an intelligent software concept and modern robotics applications: As a result, IKEA enjoys efficient and more ergonomic processes, handling flexibility as well as scalability.

Steady replenishment process and intelligent palletising
“Our original intention was to embrace this exciting concept and test the system together,” says Julien Weiß. “We provided the location and the items here in Dortmund, and SSI Schäfer installed the solution, facilitating a reliable ‘proof-of-functionality’.” The results were impressive across the board, and the partner contract to implement the real system was signed at the end of 2019. The system went live in April 2021, and the flexibly scalable flat pack picking module comprising hardware and software, which SSI SCHÄFER supplies as a complete system from a single source, was integrated into the customer order distribution centre’s existing hall, almost ten metres in height. Since it was started up, the incoming pallets are first checked for contours and weight. Then, energy-efficient SSI Exyz storage-retrieval machines perform the storage in the pallet warehouse with almost 900 storage locations. Along the hydraulic buffer aisle, four ro-ber FP150 series gantry robots, which access both statically provided A-items and dynamically provided B- and C-items within their action area, pick pallets. The gantry robots are equipped with multifunctional grippers that automatically adapt to the dimensions of the items and the type of packaging by means of servo-motor-adjustable suction cups. The gantry robots and grippers were developed by ro-ber Industrieroboter GmbH, a subsidiary of SSI Schaefer. The process is supported by vision technology in combination with the WAMAS logistics software, so that each picking robot is able to quickly identify the proper position of the requested item. Goods up to 2.5m in length and weighing more than 60kg are safely picked up from the source pallet and transferred to the ready-to-use order pallet. The removal of intermediate layers is also fully automated. The stored packing pattern generator (SSI Pack Pattern Generator) ensures a safe, optimised arrangement of the items on the order pallets, which are prepared for further processing via a buffer as part of the outbound process.

Findings of the simulation confirmed in operational use
IKEA distribution centres store an average of 10,000 different items. Tests have confirmed that 1,500 of these can be picked automatically. Ten percent of these items have been identified so the area can be optimally utilised. They are primarily fast movers, such as the PAX cabinet, the body of which weighs just under 60kg. “The reduced burden on our staff is a major plus,” emphasises Julien Weiß, who has headed the project since 2019. “They no longer have to pick bulky and heavy parts; instead, this is done by the robots. This takes an enormous amount of strain off the workforce, which is highly motivated to focus on boosting other value-added processes.”

Collaborative innovation for the furniture sector
IKEA and its employees immediately benefit from the increased performance values and automated processes. “We have enjoyed a consistently positive collaboration with SSI Schäfer , also in this pilot project,” Julien Weiß concludes. “The partnership approach favoured and lived out by both companies in particular has contributed to the success.” IKEA reserves the option of rolling out the innovative system at other locations. At the same time, the system will be of interest to other players in the furniture sector that would like to offer their customers an exceptional shopping experience across different channels, also in the heavy-load segment. This is because the solution delivers streamlined and efficient logistics processes with the help of automation, while at the same time offering employees an appealing working environment. “The innovative concept and the added value that can be achieved in real terms mean that the flat pack picking solution is extremely relevant to the market,” adds Tim Langenbach. “This is why we are excited to be able to implement this scalable system, which can be adapted to a wide range of different SKUs in the future and also provided on a turnkey basis to other customers.”

CLICK HERE to watch a video.

IFOY TEST REPORT

Ikea operates Germany’s largest customer order distribution centre in Dortmund. Together with its long-standing partner SSI Schäfer, Ikea has successfully relieved its employees of heavy physical work. Heavy and large items are palletised in a volume-optimised manner with the help of the new picking module from SSI Schäfer, employees are freed from unergonomic work. At the same time, optimal packing patterns for the order pallets are automatically generated.

How does Flat Pack Picking work in use at Ikea? The introduction of this sustainable, innovative picking concept from SSI Schäfer in Germany’s largest Ikea distribution centre was preceded by a concept study and proof-of-concept starting in 2017. By means of a test installation and subsequent simulation, Ikea put SSI Schäfer’s flat-pack picking system, implemented for the first time at the Dortmund site, through its paces – and found it to be good. The go-live started in April 2021. Both the heterogeneous range of articles and the large proportion of heavy and bulky articles were a particular challenge here. It turned out that of the approximately 12,000 stock keeping units (SKUs) located in the distribution centre (DC), about 10%, i.e. 1,200, can be handled fully automatically. These are usually the so-called “fast-moving items”.

The goal of the four gantry robots used, which are supported by two small gantry robots outside the actual picking area, was to relieve the employees of heavy tasks by means of automated gantry picking. One of the four gantry robots, with its 16 suction cups that grip the packaged goods from above and the cameras at the four corners, has a theoretical (technical) picking performance of 70 to 80 picks per hour. This makes the four robots the fastest link in the entire system. Together, the four gantry robots can handle a maximum of 312 picks; in real operation, they currently handle a good 200 picks per hour. Intermediate layers on the individual packages that get in the way of the fast lifting and transporting process of the packages are reliably detected and removed.

The turnkey, scalable order-picking solution basically consists of three areas: the left-hand part of the system for the dynamic provision of the slower-moving furniture packages, the actual picking area in the middle where the four “ro-ber” gantry robots do their work and to which no human has access, unfortunately not even for testing purposes, and the right-hand part of the system for the static provision of the fast-moving items. The gantry robots are equipped with multifunctional grippers that automatically adapt to the dimensions of the articles to be picked and the type of packaging by means of servomotor-adjustable suction cups. Packages of goods up to 2.5 metres in length and weighing over 60 kilograms are safely picked up from the source pallet and transferred to the order pallet. SSI Schäfer’s Pack Pattern Generator ensures that the requested items are optimally arranged on the order pallet and can be picked up for the customer order.

IFOY Test Verdict

According to Ikea’s own information, the new system enables the company to handle about 3,000 more customer orders per week than before. This is a great advantage because customer orders tend to be smaller, but the quantity is significantly higher. In times of e-commerce, more and more customers have their Ikea purchases delivered and also set up. However, SSI Schäfer’s sophisticated flat-pack picking solution can also be adapted to a wide range of different SKUs outside the furniture industry and is therefore highly interesting for other industries as well.

IFOY INNOVATION CHECK

Market relevance: The challenge of picking large and at the same time carton-packed packages has long been known in logistics. As a rule, teams of two order pickers or one order picker with a mechanical lifting aid, such as a balancer, must be used for this. The solution presented is very attractive for this market segment. However, an essential prerequisite for successful use is reliable and stable carton packaging to implement the gripping process with vacuum suction pads.

Customer benefit: If the aforementioned prerequisite is fulfilled, the solution offers both an ergonomic benefit through the relief of the employees and a benefit through the automatic provision of the article pallets for picking. The latter function reduces the load on the supply warehouse for order picking, as the article pallets are held in the staging area for flat pack picking according to their access frequency and are made available for access at the exact time. Together with the precisely specified stacking sequence and the automated movement of the customer order pallet through the picking system, this results in a stable and reliable build-up of the load.

Novelty: The well-known picking task of flat pack picking has never before been implemented so consistently and efficiently in an automated system. The clever design of the material flow of the article pallets combined with the flexible gripping technology for handling the carton-packed parcels account for the high degree of innovation, which has not been achieved before.

Functionality / type of implementation: The functions are very well and appropriately designed for the application at IKEA. According to the information provided by the developer SSI SCHÄFER and the user IKEA, the limitation of the achievable throughput does not result from the robots with their grippers but from the capacities for cross-distribution of the customer order pallets and the article pallets with distribution trolleys. For a general use case, there is therefore still potential to make the function more adaptable for different order compositions.

Verdict: Not all interested users will have the prerequisites of stable and flat carton packaging. However, if these are given, it is a relevant and innovative solution for efficient order picking.

market relevance Ø
customer benefit ++
novelty ++
functionality / type of implementation +
[++ very good / + good / Ø balanced / – less / – – not available]

For an overview of all the finalists, visit www.ifoy.org

CLICK HERE to find out more about Flat Pack Picking by SSI Schäfer.

Linde launches electric trucks up to 18 tonnes

Posted on by David Priestman

Linde Material Handling (Linde MH) now offers a new range of electrically powered heavy-duty forklift trucks with load capacities from 10 to 18 tonnes. Twelve models in total impress with excellent all-round visibility and provide maximum flexibility with a choice of either lead-acid or lithium-ion battery systems.

Offering load capacities of 10, 12, 14, 15, 16 or 18 tonnes and various load centres, the Linde E100 to E180 trucks are a particularly interesting option for companies operating in the wood, steel and stone industries and the beverage sector. One of the first customers also includes a major furniture company.

“Zero emissions, quiet operation, high serviceability, flexibility in use, and precise and agile driving characteristics – these advantages clearly speak in favour of using the electric drive in the heavy-duty class as well,” says Christopher Reis, Product Manager Heavy Trucks.

“With the electric heavy-duty forklift, our customers get a vehicle that is just as worthwhile for light duty as it is for 24/7 continuous use.” Operators have a choice between lead-acid and lithium-ion battery systems. “However, the special feature is that they can even swap the battery technology at any time without having to change the hardware. This is a truly unique selling point of these vehicles and offers a significant advantage not least in terms of subsequent use,” emphasises Reis.

A special drive concept with four motors – two for the left and two for the right wheel – provides the necessary power for transporting the remarkably heavy loads. This enables the most powerful model, the Linde E180/900 with 18 tons load capacity and a load centre of 900mm, to reach a driving speed of 20km/h within just 10 seconds even when fully loaded.

The electrification of the largest truck series means that Linde MH’s entire portfolio of counterbalanced trucks in the load range from 1.4 to 18 tonnes is now available with the most common types of energy technology. Thus, the intralogistics specialist is able to offer its customers the option of selecting the appropriate drive for the specific application at hand, even in the largest payload class.

The development of the large Linde electric forklifts has been aided by more than 50 years of experience with this drive concept. “The use of proven technology ensures high reliability in operation – which is a particularly important feature for our customers,” emphasises product manager Reis. For instance, the design of the new, compact heavy-duty truck series is based on the eight-tonne range, featuring a double drive, double lifting hydraulics, two batteries and scaled pumps.

The decoupled, rubber-mounted cabin design is borrowed from the smaller forklifts as well, but has been significantly improved once again in terms of all-round visibility: An armoured glass roof and large glass panes in the side doors as well as the front screen and rear windows, in combination with the specially shaped counterweight, provide the driver with the best-possible visibility and thus safety during operation. The driver’s seat is optionally rotatable by 17° and offers an armrest, providing relief when reversing.

The orange seat belt with belt buckle monitoring function helps with implementing the safety belt obligation. To enable the battery system to be adapted to different application requirements, there are various battery and charger versions available.

 

Recognising the value of reconditioned attachments

Posted on by David Priestman

Investing in a used forklift attachment in a great condition is a cost-effective way of upgrading your material handling equipment at a pre-owned price, according to B&B Attachments.

With over 40 years’ experience in the UK and Ireland forklift truck attachment market, B&B Attachments is in a unique position to provide reconditioned clamps to meet its customer’s requirements.

B&B Attachments specialises in the design and manufacture of forklift truck attachments and material handling solutions. The company’s extensive workshop facilities allow its experienced fitters to meet the challenge of providing high quality reconditioned and refurbished clamps. All attachments are inspected, serviced, repaired, and tested. They undergo a rigorous remanufacturing process where original equipment manufactured parts are used wherever possible. Its range of used forklift attachments are available in mounting classes II, III and IV.

“All B&B’s reconditioned attachments are thoroughly restored back to their original condition with some of the most experienced industry professionals finding it hard to tell them apart from new stock,” comments Sales Director, Neal Fowler. “All units are backed by our 3- or 6-month warranty options, with dedicated sales and service teams providing full technical backup and support. All reconditioned attachments are sold with Thorough Examination Certification included.

“Or why not test out our attachments before buying, with our dedicated hire fleet of over 2,500 attachments, available through our European network. All attachments are available on flexible long- or short-term hire agreements to suit the hirer’s need. Whether the requirement is a week, a month, or a year, B&B have the solution that works best for you.”

 

Hyster launches flagship A Series forklifts

Posted on by David Priestman

Hyster has launched its new Hyster A Series lift truck series, with the H2.0-3.5A internal combustion models now available. The A Series trucks are designed specifically for each customer using A+ Logic, a fully integrated set of scalable and adjustable features that allow users to fine-tune the truck to match their specific application needs.

“For the A Series, Hyster has revolutionised its manufacturing process to deliver the tough, high quality lift trucks that you expect, built around the particular needs of the intended application and the operator,” says Robert O’Donoghue, VP Marketing and Solutions EMEA, for Hyster. “That’s why we describe this series as ‘Distinctly Hyster, built for you’.”

With A+ Logic at the core, the A Series lift trucks can be easily configured to fit each customer’s unique needs, delivering superior performance for the specific operation as well as a low total cost of ownership. The scalable design philosophy makes it easy for customers to add the features that are needed for productivity in their operation and avoid paying for unnecessary options that increase cost without adding value.

“We have designed the trucks this way as no two customers face identical challenges,” says Robert. “With the Hyster A Series, instead of providing you with options for a truck we already built, we build the truck you need according to your duty cycle, environment, and tasks.”

The Hyster H2.0-3.5A internal combustion lift trucks with capacities from 2 to 3.5 tonnes are the first trucks to be released in the series. Not only are they highly configurable, but the base models offer industry-leading fuel economy, excellent visibility, simplified service, and robust components that help prevent unplanned downtime.

“Operator confidence and comfort are tremendously important as they help to enhance productivity,” explains Robert. “That’s why the new A Series lift trucks feature operator-centric design to support proper ergonomics and high performance.”

The spacious operator cabin on the H2.0-3.5A trucks is specifically engineered to emphasise overhead, forward, and rear visibility and give the operator greater freedom of movement to help reduce strain on the body. This attention to design makes the lift truck comfortable and convenient to operate, helping to increase productivity across the whole shift. Additionally, there are available features including operator assistance systems and an innovative Dynamic Stability System (DSS) option.

All A Series trucks are also ‘telematics ready’ for use with the Hyster Tracker wireless asset management solution, which gives businesses the data needed to optimise their fleets, control costs, reduce downtime, and streamline maintenance even further.

The newly released models replace the Hyster Fortens and XT lift trucks at the same capacity. The A Series is expected to expand to include other Hyster IC lift trucks in various capacities in due course.

 

Forklift accidents are a global concern

Posted on by David Priestman

Unfortunately, no matter where you go in the world, forklift-related workplace accidents are far too common. Recent events from around the globe demonstrate this unsettling fact.

  • In the United Kingdom, a reversing forklift at a goat milk producer struck and killed a woman, resulting in a £200,000 fine.
  • In Canada, the Minister of Labour is investigating the death of a worker struck by a forklift at an Ontario steel company.
  • In Singapore, 3 out of 20 workplace fatalities so far this year have involved forklifts.

In the UK, forklifts account for more workplace accidents than any other machine, and 57% of all people injured by forklifts in the UK are pedestrians. In the US, the Occupational Safety and Health Administration estimates that if companies implement more stringent safety and training policies, forklift accidents could be reduced by 70%.

As the statistics and recent forklift accidents attest, any workplace that requires pedestrians to work near mobile equipment, like forklifts, must take pedestrian safety seriously and implement protective measures to keep their workers safe.

Keeping workers safe

SEEN Safety has addressed the persistent global issue of pedestrian safety head-on with its world-class IRIS-860 sensor. Through cutting-edge technology, their sensors have improved workplace safety for countless pedestrian workers around the globe who work in close proximity to forklifts and other mobile equipment.

SEEN works with companies in various industries where people and material handling machines work closely together – such as distribution centres, manufacturing, and logistics warehouses. They make sensors designed to detect when an employee has entered a critical area around mobile equipment like forklifts or wheel loaders. If a worker enters the area behind reversing equipment, the IRIS-860 sensor will audibly alert the driver to their presence.

SEEN’s sensors are simple to use. With the IRIS-860 sensor, workers do not need a complicated battery-operated transponder. Instead, the sensor identifies workers by transforming one of the most commonly used pieces of personal protective equipment, the high visibility vest, into part of an active safety system that is immediately effective and easier to implement than other options on the market.

The hard work of detection is done by SEEN’s infrared sensors, which work well beyond what an optical camera can ‘see’ in the visible light spectrum. SEEN deliberately uses infrared for detection, it is extremely reliable regardless of dust & dirt, weather and variable lighting – conditions commonly encountered in materials handling operating environments. Failure to detect reliably may be ok if people aren’t close to the machine when it’s operating, but it’s crucially important when a person enters the high risk zone behind a reversing machine.

In addition the sensors can be configured to meet the requirements of a specific worksite. Often, the operator is focused on their load which is usually in front of them creating a blind spot behind the machine, this is the area where pedestrian collisions can be the most catastrophic. SEEN’s sensors are designed to be configured to target that area precisely and reliably, focusing on the detections that really matter and minimising nuisance alerts.

The system is effortless to use, requiring zero specialist knowledge to install or set up, and always offers reliable protection, regardless of conditions. The sensors are also significantly more cost-effective than other alternatives, making it possible to spread them across your entire mobile equipment fleet.

 

Clark launches forklifts with higher load capacities

Posted on by David Priestman

Clark‘s globally coveted S-Series celebrated its debut in 2018. With the special “Smart, Strong and Safe” features of the counterbalance trucks, Clark set a benchmark for future truck generations back then. Now the materials handling vehicles manufacturer is expanding the popular series to include IC engine-powered trucks with load capacities of 4 to 5.5t.

Like their smaller counterparts with load capacities of 2 to 3.5t, the new models are also equipped with active safety systems, a smart information system and extensive additional equipment. Operators can tailor the trucks to their individual use and thus achieve high productivity at a low total cost of ownership (TCO), says the manufacturer. And the operator does not miss out either thanks to the excellent ergonomics and safety of the trucks.

The new S-Series models consist of the S40-S55 diesel and LPG forklifts with superelastic or pneumatic tyres. The trucks are the first choice for both medium-duty and extremely tough applications. Wherever high handling performance and availability are crucial – such as in multi-shift operations in industry, trade and distribution, in the paper and beverage industry or in demanding foundry operations – the trucks score with their robust design, reliable, safe and powerful operation and low operating and maintenance costs.

Strong – robust and low-maintenance

The construction basis of the S-Series is, as usual with Clark, the proven “Built to last” concept, which is based on more than 100 years of experience in forklift construction. It stands for a solid construction with high-quality and durable components. The forklifts have, among other things, wet maintenance-free multi-disc brakes, a durable and electronically protected gearbox, tried and tested lift masts from our own production with a robust 6-roller fork carriage, an extremely stable steering axle as well as the fully welded frames familiar from Clark.

Powerful Kubota industrial engines are used in both the diesel and LPG forklifts of the S-Series. The Kubota 4-cylinder diesel engine with common rail fuel injection V3800-CR-TE5B has a fully electronic engine control. This not only makes it environmentally friendly, but also provides an optimised torque curve and more economical operation. Due to the integrated exhaust gas aftertreatment with diesel oxidation catalyst (DOC) and diesel particulate filter (DPF), the Kubota diesel engine, like the LPG engine, meets the strict exhaust gas standards of EU Stage 5.

Operators can look forward to low operating and maintenance costs with the S-Series. The vehicles have, for example, maintenance-free multi-disc brakes with oil cooling, which also show their strong braking effect on wet or dusty ground. At the same time, the brake booster ensures that less force is required for braking. The long maintenance intervals should also be emphasised. In case of maintenance, all relevant components are easy to reach for the service technician. Downtimes are therefore kept to a minimum.

Active safety systems

Clark offers the S-Series with numerous safety features: These include the standard automatic engaging parking brake, which is automatically activated when leaving the parked vehicle and makes the operator’s daily work much easier. The truck control system prevents the forklift from starting against the parking brake. This not only increases safety, but also contributes to longer component durability.

The parking brake also increases safety on ramps. The operator always has the truck under control, as unintentional rolling away or back is prevented. This anti-roll-back feature is standard and can be activated or deactivated via the truck’s control system. Safety and comfort are also ensured by the direction switch integrated in the hydraulic or mini-lever. This allows the driver to change the direction of travel without having to reach around.

The load weight indicator is available as an option. This measures the weight of the load on the forks and helps the driver to avoid overloading the truck. With the Vertical Mast System (VMS), which is also optional, a tilt sensor automatically brings the mast into a vertical position so that goods can be stored and retrieved quickly and safely. The VMS positions the mast vertically both when tilting forwards and backwards and compensates for the vehicle position on uneven floors or ramps.

In order to adapt the maximum travel speed of the truck to the application profile, a speed limiter is optionally available. And last but not least, Clark offers a car-like reversing camera for safe reversing, with the aid of which the driver has an optimum view of the activities in his path when reversing.

Ergonomic driver’s workplace

The ergonomic workplace concept of the S-Series offers the driver a high level of comfort. This starts with the entry: the driver can comfortably get on and off the truck via the wide non-slip step and the large grab handle. In the spacious interior, the driver enjoys the best head and legroom. Clark has placed the tilt cylinders under the base plate on the new series, thus ensuring unobstructed entry and exit.

The comfortable full-suspension seat with safety belt has a folding backrest and can be adjusted to the weight of the driver. To increase safety during forklift operation, the transmission and direction switch can only be operated when the seat belt is fastened by means of appropriate additional equipment. The ergonomic steering wheel, automotive-style pedals and hydrostatic power steering allow the operator to control the truck intuitively and without effort.

The vehicle is operated either by hydraulic levers attached to the bonnet or, optionally, by mini-levers integrated into the fully adjustable, swinging armrest. The movements required to operate the levers are minimal, relieving the strain on the driver’s arm-shoulder area.

The splash-proof 5-inch TFT colour display provides information on all important vehicle parameters, such as travel speed, load weight and operating time until the next maintenance. Safety and warning messages can be individually programmed and are displayed in 26 languages. In addition, the display is used for onboard diagnostics and has password-protected access in case of service. If desired, to save fuel and increase safety, the vehicle can be programmed so that the engine automatically shuts off at idle as soon as the driver leaves the truck seat. When a reversing camera is used, the image is transmitted to the colour display.

The overhead guard provides a good view upwards when storing and retrieving high racking levels. All mast variants with free lift have double primary cylinders so that the driver also has an unobstructed view of the forks and load to the front. By decoupling the engine, transmission and drive axle, Clark has reduced vibration and noise to a minimum so that the driver can concentrate on his work. A wide range of storage options, a 12 V power connection and, on request, a radio or an additional USB charging port, e.g. for mobile phone devices, round off the workplace.

Extensive additional equipment

Clark offers the S-Series with extensive additional equipment for a variety of different applications: These include container-compatible driver’s protective roofs, a reversing camera, a Safety Light for visual warning when driving forwards and backwards, an acoustic reversing alarm, various seats with armrests or side bars, SE tyres, orange safety belt and a wide range of attachments.

In addition, various cab variants are available: these range from rain (cab roof) or weather protection (roof and windscreen) to a partial cab (roof, windscreen and rear window) to a fully equipped full cab with two-part side door and sliding window, air conditioning, heating with proportionally controllable heating valve, heated rear window and front and rear windscreen wipers, so that the driver can work in concentration and comfort even in the harshest climatic conditions.

 

EFFIMAT brings SINA to LogiMAT 2022

Posted on by David Priestman

EFFIMAT is bringing its SINA automated solution to life once again together with its German partner Ecosphere Intralogistics at LogiMAT 2022 in Stuttgart.

SINA – Smart kitting solution for Intralogstics Automation – a solution that automates the intralogistics and material handling processes, in for example production, from inbound to delivered kitted items directly at the production line.

The solution can also be applied to 3PL and e-commerce businesses by automating the order handling process. This makes companies able to operate flexibly 24/7 at a low picking cost.

SINA has its origin in EFFIMAT Automated which work with the thought of connecting various robotics solution, matching the customer’s needs. SINA became the result of eight partners coming together with some of the absolute best solutions within each of their product range and of course the knowledge of integration.

SINA is built around the EffiMat, which is a tote-based solution for storage and handling of items. The patented technology within the EffiMat ensures fast picking and the design allows picking processes to be more dynamic and efficient as five totes are presented in every picking cycle. This technology and design make EffiMat the optimal goods-to-robot solution.

Optimal components

To automate the picking and kitting process the most essential components was added. In the front the UR10e collaborative robot is placed to secure efficient picking. With its payload of 12.5kg and large reach of up to 1,300mm and high level of flexibility the UR10e is perfect for the SINA setup.

Attached to UR10e is the Piab MX suction cup. This suction cup is a real all-rounder and is ideal for holding all products, regardless of what material the product is made of or what surface and finish is has. To ensure picking accuracy the AI-based robobrain.vision from robominds has been added.

For safe transport of the kitted items to production line, the AMR MiR250 is used together with the TR125 top module from ROEQ. The top module can recognize and precisely control the loading station via its WLAN-independent optical measuring system.

To make the SINA solution safe, the sBOT nanoScan3 from SICK is mounted on the solution to ensure that the speed of the solution reduces the closer an employee comes to the solution and stops entirely if the employee comes too close.

The intelligence behind SINA

Every solution like this needs a software to connect all the pieces. EFFIMAT Connected was developed for this exact purpose. With a simple interface the software connects all components to the EffiMat, making it a complete and efficient solution.

If needed EFFIMAT connected can be integrated with the customers ERP system, which enables seamless kitting and order handling.

Ecosphere Intralogistics has been the integration partner on the SINA project. It has been taking care of everything from plugging in the components to testing and optimising the entire SINA Solution. Ecosphere Intralogistics will be the EFFIMAT partner in Germany, who will take care of sales of SINA in the German region.

At LogiMAT 2022 in Stuttgart, the eight partners are once again coming together and EFFIMAT will together with Ecosphere Intralogistics be showcasing SINA. You will find SINA in hall 5 at booth F60 where it will showcase how kitting can be handled. Further EFFIMAT and Ecosphere Intralogistics is bringing something new – an updated, even better SINA.

 

Stow Robotics acquires iFollow

Posted on by David Priestman

Stow Robotics, stow Group’s warehouse automation business unit, has acquired a majority stake in iFollow SAS, a collaborative autonomous mobile robot company.

Reinforcing stow’s commitment to warehouse automation, stow Robotics was launched in September 2021, regrouping all existing automated solutions for pallets and totes and related services and teams. Through this newly created and dedicated business unit, stow is building a platform of scalable and innovative automated solutions and continues to invest in ground-breaking technologies such as iFollow’s robot and software offering.

iFollow, founded in March 2017, is a Paris-based robotics company developing and commercialising market-leading autonomous mobile robots and a proprietary software suite. Its present fleet of cutting-edge AMRs and software are suited for a large range of use-cases, such as collaborative picking and in-and-outbound transport. iFollow is currently accelerating the commercialisation and deployment of its AMRs, having already deployed its technology in a wide variety of applications across different industries and building on a promising pipeline.

The acquisition of iFollow is backed by funds managed by Blackstone, stow Group’s majority shareholder. The partnership with iFollow’s management, who remain on board, strengthens and builds on stow Robotics’ clear strategy and leading position in the global warehouse automation market.

Jos De Vuyst, CEO of stow Group, said: “We are thrilled to welcome iFollow to stow Robotics and have been impressed by the entire iFollow team. This is another important milestone for stow Robotics, adding a company that fits perfectly within our portfolio of scalable automation solutions. We truly believe this partnership will unlock significant synergies with our Atlas 2D pallet solution, as well as meaningfully accelerate iFollow’s growth through our commercial network. iFollow shares in our vision for the future and provides the perfect platform for further AMR-based solutions.”

Vincent Jacquemart, co-founder and CEO of iFollow, said: “We are delighted to join forces with stow Robotics, a leader in warehouse automation. We firmly believe this is the right partnership to start iFollow’s next phase of long-term growth, with a reliable, global partner. In addition to its commercial traction, technology-driven approach, and its advanced industrial base, we share with stow the same conviction on the importance of technology in warehouse automation and the future of intralogistics. It’s a very exciting moment for our team, which is looking forward to shaping the industry even further.”

 

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