Subscribe

Tag: warehouse automation

Radnor Hills gains efficiency with robotic palletisers

Posted on by David Priestman

Robotics and automation specialist RMGroup has installed three of its end-of-line robotic palletisers for award-winning soft drinks business Radnor Hills. The move has enabled the manufacturer to benefit from process efficiencies throughout its production.

Manufacturing a wide range of spring waters, flavoured waters, functional waters, school compliant drinks, premium sparkling pressés, fruit juices and own-label brands, Radnor Hills first approached RMGroup in 2018 to investigate automating an end-of-line palletising operation with a robot arm.

On the line, packs of bottles needed to be palletised at a rate of 14 packs per minute. Given the throughput and pallet stack formats, RMGroup needed to ensure that the robotic solution could multi pick packs up to four at any one time, and then place them onto a pallet in ones, twos, threes or fours, to keep up with the production line throughput.

By using ABB robot studio, RMGroup’s mechanical design and technical department recommended the use of a bespoke gripper, thereby enabling the robot to stack the packs onto pallets at the desired rate. Robot studio also helped RMGroup to decide which ABB robot would be best suited for the project, thereby optimising the ROI.

Following the success of the initial installation, RMGroup has since supplied another two ABB end-of line palletisers at the site. A second was installed on Radnor’s tetra pack line, the requirement being to palletise cardboard cartons from dual production lines at a rate of six cases per minute; a third line was installed on Radnor’s canning line, involving a much higher output of 24 packs, 12 of which needed to be palletised on euro pallets, at 20 cases per minute.

“The benefits of working with RMGroup and what we feel they particularly do well, is first and foremost they listen to us,” said David Pope, Radnor Hills’ general manager. “They take on board our requirements – they don’t tell us what we should be doing, they listen and come back with us with solutions to make it happen. The whole team has been a pleasure to work with, especially the engineers, who have been extremely knowledgeable and helpful throughout the whole process.”

William Watkins, Radnor Hills’ managing director, added: “I think RMGroup’s experience, their backup and the fact that they have a very conscientious team, means that they really make sure that they don’t leave you until you are absolutely 100% happy that the machinery they’ve installed is working absolutely as you expect it to.”

Strapping machine secures single and double pallets economically

Posted on by David Priestman

 

With two-in-one functionality for pallet strapping, Mosca introduces the flexible, high-performance KZV-321 strapping machine. It easily adapts to a variety of product shapes and is ideal for logistics and transport of goods.

“The KZV-321 is the latest addition to our portfolio. It is an extremely adaptable high-performance strapping machine designed to secure goods for transport on pallets. This model makes it possible to strap single and double pallets at different heights with just one machine. Until now, this operation required two different machines,” explains Mosca CEO, Timo Mosca.

To combine the two applications, the KZV-321 is equipped with an open strap frame and six movable strap lances at three different heights. The machine automatically detects the height of a product as it enters the machine. The strap lances then close the frame at the appropriate height and the KVZ-321 securely straps the package.

Timo Mosca: “This new machine variant helps us support our customers by making their processes more efficient and reliable.”

The KZV-321 straps up to 130 single pallets or 65 double pallets per hour. The machine can be optionally equipped with an integrated turntable that enables it to efficiently secure two pallets for transport. The KZV-321 first straps each pallet separately to create a stable bundle.

A machine operator or automatic pallet doubler then stacks the two pallets on top of each other. This stack is fed into the KZV-321 again and, if necessary, realigned on the turntable. Finally, the machine’s strap lances pass through the planks in the base of the upper and lower pallets. This second strapping creates a stable bond between the stacked pallets.

“By strapping the double pallet through the pallet bases, the KZV-321 introduces a completely new process to the market that automatically and efficiently creates a stable unit,” explains Christian Zwieb, Sales Manager at Mosca Engineering. The straps are threaded through the planks in the pallet base and therefore do not touch the products. This allows maximum strap tension without damaging the product.

“The strapping simply attaches the top and bottom pallets and does not need to be placed around the entire stack. This ensures maximum stability, saves consumables, lowers costs and helps protect the environment,” adds Christian Zwieb.The two-stage securing process also makes it easier to split double pallets again without affecting the bond between pallet and product. The straps are removed quickly and easily without leaving any residue.

To ensure optimum machine availability and energy efficiency, the KZV-321 is equipped with the Mosca SoniXs ultrasonic sealing unit that has been tried and tested in high-performance machine operations. This unit does not require warm-up and efficiently seals strap ends with minimal wear.

To simplify maintenance and service, the two sealing units are located on the side of the machine and close to the floor. The KZV-321 is more compact and lower than previous KZV versions. “This machine requires less space, is easily accessible for operators and easy to maintain,” says Christian Zwieb.

The modular design of the KZV-321 also allows users to choose individual strap spacings. The standard is currently 480 millimetres. “Depending on the type and composition of the product to be strapped, we can adjust the strap spacing to customer specifications,” explains Christian Zwieb. The machine ensures safe transport of goods across all industries including intralogistics: for example, products packed in plastic containers or cartons, barrels or bags and stacked on pallets. This makes the KZV-321 a good choice for manufacturers from a wide range of industries, including food, chemicals, construction or agricultural products.

“No matter what type of packaging is used for goods stacked on pallets, the KZV-321 can be adapted to a wide range of dimensions and formats to optimally secure products for road, sea or air transport,” concludes Timo Mosca.

Energy-efficient motors set new standards

Posted on by David Priestman

Considerably lower losses than the IE4 series: The energy-efficient IE5+ permanent magnet synchronous motors from Nord Drivesystems are particularly characterised by high efficiency and a wide torque range.

This makes them optimally suitable for economic operation in the partial load range. The new IE5+ motors are equally interesting for both intralogistics and hygiene-sensitive areas in food and pharmaceutical industries. Last year, the compact IE5+ motor of size 71 was presented, and now size 90 is also available for power ranges from 1.1 to 4.0 kW with a continuous torque of 6.8 to 18.2 Nm.

The motor ensures the usual Nord flexibility: Direct motor attachment as well as NEMA and IEC motor attachment are available. Rotary encoder and mechanical brake integration is available on request.

The IE5+ synchronous motors in two sizes with a smooth motor design are ideally suited for wash-down applications in food and pharmaceutical industries.

Due to the constant torque providing a targeted reduction of variants over a wide speed range, administrative expenses can be minimised, and manufacturing, logistics, storage and service processes can be streamlined.

The investment pays for itself within a short time. The IE5+ synchronous motors can be combined with all gear units and drive electronics from Nord Drivesystems in a modular system. This results in a system solution from a single source in which all components are seamlessly matched.

 

 

Edeka automates its fresh produce logistics

Posted on by David Priestman

Part of Germany’s largest supermarket chain, the regional company Edeka Minden-Hannover is automating its fresh produce logistics in the fruit and vegetable sector with an intralogistics solution from Cimcorp, which has specialised in this automation for over 40 years.

Together with other Edeka regions and the Netto Marken-Discount chain, the regional company Edeka Minden-Hannover is one of the first German grocery retailers to use this solution.

Cimcorp has already provided similar automation for the fruit and vegetable sector in other European countries. Jarno Honkanen, Director of Solution Development at Cimcorp, says: “We’ve provided reliable solutions for rapid order fulfilment for many years, thereby optimising the shelf life of perishable products. The advantage for customers is that they receive their fresh products faster and that they stay fresh longer in the household. We look forward to working with Edeka on this further project.”

“The Edeka slogan is ‘We love food’,” explains Arnd Wilde, Logistics manager at Edeka Minden-Hannover, “which is why our regional company offers a comprehensive range of products in its Edeka stores, secured by professional quality management: from inexpensive basic items to branded items and selected specialties. Supported by our cooperative guiding principle, we rely on our independent Edeka merchants and store managers to have a high level of commitment in the joint business venture.

“Our daily challenge is to bring fresh fruit and vegetables from the producer to our markets promptly. This is often a race against time, because it usually takes only a few hours between delivery to our warehouse and delivery to our stores. In Cimcorp, we have found a partner who can provide us with a solution for fully automated order picking of ergonomically packed fruit and vegetable pallets that meet the requirements of our markets – quickly, reliably and cost-effectively. This automation does not mean that jobs are lost; we need our full team to continue to provide the desired logistics service for our salespeople in the future.”

Quality and freshness are critical for customers when buying groceries in-store. This means that speed and accuracy in picking are crucial for product quality. Edeka Minden-Hannover is constantly working to optimise its logistics processes and is thus continuing its sustainability strategy with a view to reducing CO2 emissions, among other things. In order to meet these challenges, Edeka Minden-Hannover, as the largest grocery retailer in its sales area, continuously invests in the modernisation of its logistics.

Around 1,200 fruit and vegetable items for the 1,488 supermarkets in the region are freshly picked and delivered daily to the four logistics centres located in Lauenau, Freienbrink, Wiefelstede and Landsberg. The aim is to modernise two of the existing logistics centres – Lauenau and Freienbrink – with minimal disruption to daily operations and without risking food safety. These two logistics centres will supply fresh fruit and vegetables to more than 1,000 stores every day.

In Lauenau, the automation will be installed in the existing logistics centre, which has been fully operational since 2014. The volume is higher in Freienbrink, so a total of three fresh food modules will be installed there. The modular structure speeds up the installation: once the first fresh food solution is in operation, the next two will be installed.

Jarno Honkanen, Director of Solution Development at Cimcorp, says: “When fully operational, the modularity guarantees the maximum functionality of the system through redundancy. The individual module can be emptied – for example, during cleaning – without interrupting the entire flow of materials in the logistics centre. Overhead gantry robots handle food crates that are stacked on the floor – there is no need for an expensive shelving system.

“This is also essential for food safety. During cleaning, crates can be moved to another module or stacked under the gantry robot to clear the floor. An empty floor is easy to clean, which ensures a high standard of hygiene.”

Lödige further develops goods lifts

Posted on by David Priestman

Lödige Industries has further developed its proven Sherpa and Escorta chain lifts. With a 50% higher load capacity of now up to 4.5 tonnes as well as a larger cabin, both are able to even better meet customer requirements for the transport of heavy and bulky loads.

Customers can now increase their productivity and speed up throughput by moving more every single time. The advantages of the compact machine room-less solution with self-supporting steel frame shaft remain unchanged. The latter is also available powder-coated in RAL Classic colours. With nominal loads from 3t, these lifts can now also be installed or retrofitted in existing concrete or masonry shafts.

In industrial and commercial environments, the compact and easy-to-install lifts with a lifting height of up to 18m have proven their worth for many years. The models Sherpa, a goods-only lift, and Escorta, a goods lift with attendant, are used by logistics companies, in production facilities and supermarkets but also in hospitals, hotels and office buildings.

Especially in the warehouses and distribution centres of large e-commerce companies, a space-saving solution with the highest possible performance is in demand. Thanks to the customised cabin, they can be flexibly installed in existing buildings or racking systems without having to make structural changes. By means of a low access ramp, installation without a pit is also possible.

Until now, the load capacity of both models was limited to a maximum of 3t and the cabin depth to 3m. The further development enables the transport of up to 4.5t and a maximum cabin depth of 4.5m in the versions both with and without an accompanying person. With regard to the cabin dimensions, special solutions for individual requirements are also possible.
Both models are type-tested according to the Machinery Directive 2006/42/EC.

“With the further development of our Sherpa and Escorta goods lifts, we are responding to frequently expressed customer requests for higher load capacities and larger cabs with a suitable solution. The decisive factor was to retain the proven advantages of the compact and easy-to-install systems. As a result, our new solutions combine performance and flexibility in a way that is unique on the market,” says Sascha Haase, Product Manager Lift Technology at Lödige Industries.

For even larger loads, conversion to hydraulic solutions is required. For transporting up to 15t, Lödige Industries offers a suitable solution with the Olympus goods lift.

Smart Pallet Mover provides performance boost

Posted on by David Priestman

With the new Smart Pallet Mover (SPM), Interroll has launched a solution that can be adapted as a flexible and modular pallet management system to meet a wide range of application requirements in industrial manufacturing.

The customer and user benefits of the Smart Pallet Mover are impressive: Those who use it can now finally automate work processes in front of the machine production to avoid manual activities in safety-critical areas and manage the pallet work flow by buffering, sorting, sequencing and carrying at the right time to deliver significant improvement of the machine down time optimising the return on investment (ROI) of the machine production cells.

This not only eliminates costly production interruptions for material supply to machines, but also the risk of accidents during operation. In this way, productivity increases of up to 30% are possible compared to manual operation.

The Smart Pallet Mover is a pallet management solution for automating pallet transport in the vicinity of manufacturing machines and for production-related picking and sequencing processes, which can also be used in Industry 4.0 environments. The SPM is designed to transport, sort and buffer boxes or pallets weighing up to 1,000kg. It represents a mobile and autonomously acting material flow system that can be used, for example, as a cost-efficient supplement or substitute for forklifts or automated guided vehicles (AGVs).

The Smart Pallet Mover solution consists of various modules. The centre of the solution is a mobile unit (SM1000 Mover) that runs underneath non-driven conveyor sections and moves pallets lying on them. A transfer car (SM2000 Transfer Car) which moves on a rail can transport pallets between parallel conveyor sections.

“With this platform solution, which is unparalleled on the world market, we are tapping into the great productivity potential offered by production-related pallet management automation for our customers and users. A user-friendly 3D online tool, the SPM Layout Configurator & Pallet Flow Simulator, makes it possible to configure a system quickly and easily as well as simulate planned operation on the computer,” explains Jens Strüwing, Executive Vice President Products & Technology at Interroll.

The flexibility of this innovative solution, the use of proven technologies and a very short payback period ensure that users can significantly strengthen their competitiveness. As with all Interroll products, the Smart Pallet Mover is extremely easy to install, operate and maintain. The modular plug-and-play solution can therefore be put into operation without lengthy interruptions to production, even during modernisation projects.

Networking capabilities based on global data standards such as REST API and JSON ensure maximum compatibility and ease of use. The conveyor modules can be reconfigured very easily if required, and height-adjustable supports allow the system to be installed even on uneven floors.

Before the official market launch, the new solution had already won two internationally renowned awards. The Smart Pallet Mover won the Red Dot Award, Product Design 2021, for its exceptional design quality and degree of innovation. At the same time, the solution was chosen by the independent experts of the “International Intralogistics and Forklift Truck of the Year Award (IFOY AWARD)” in March 2021 as a finalist of this globally renowned intralogistics award.

With this new offering, Interroll is taking into account the fact that production managers are increasingly focusing on material handling, as shown, for example, by the survey “Production Logistics in Medium-Sized Businesses,” which Interroll published last year: The average degree of automation of internal material transport at the companies surveyed was only 53%. Almost every tenth company (9%) had a degree of automation of less than 25%.

NORD launches toughest industrial gear units

Posted on by Keith McKinley

The overall portfolio of MAXXDRIVE parallel and right-angle gear units from NORD Drivesystems offers high-output torques from 15 to 282 kNm across 11 sizes. In addition to this proven standard series, NORD Drivesystems offers the new MAXXDRIVE XT series with right-angle gear units having a thermally optimised design in seven sizes from 15 to 75 kNm.

In combination with its comprehensive accessories and options programme, the modular system allows for the planning of perfectly matched drive systems for heavy-duty applications like conveyors or agitators.

MAXXDRIVE industrial gear units are used when high output torques and powers are required. In combination with the suitable accessories, MAXXDRIVE provides a technically and economically perfect drive solution for each customer project. MAXXDRIVE industrial gear units are used when high output torques and powers are required. In combination with the suitable accessories, MAXXDRIVE provides a technically and economically perfect drive solution for each customer project.

The comprehensive configuration and mounting options of the MAXXDRIVE industrial gear unit allow for standardised as well as tailor-made drive solutions. The combination of motor, gear unit, coupling and braking system, for example, results in precisely planned complete units that are supplied ready-to-install, mounted on a motor swing base or a base frame. As an alternative, the motor attachment can be realised via an IEC/NEMA adapter.

A large variety of available flange and output shaft versions ensures that the customer’s application is ideally matched. The mechanical and thermal design of all NORD industrial gear units is always based on the existing operating data of the application and on the ambient conditions at the installation site. Thus, the MAXXDRIVE portfolio ensures maximum individualisation, creating drive systems that fulfil the highest demands in terms of reliability and long service life.

Variety of options

Typical MAXXDRIVE applications are drives for conveyor belts, consisting of an electric motor, a coupling solution and an industrial gear unit with axial fan. The primary focus here is on a sufficient heat dissipation to allow for ultimate thermal limit powers. The new MAXXDRIVE XT industrial gear units with their heavily ribbed housings are ideally suited for this purpose. The power and speed ranges of the application-optimised two-stage right-angle gear units have been specially designed for applications in which low speed ranges are required in combination with high powers.

MAXXDRIVE XT series output torques range between 15 and 75 kNm with speed ratios of 6.3 to 22.4. MAXXDRIVE XT industrial gear units are available in seven sizes for powers from 50 to 1,500 kW. Another typical application for this strong range of industrial gear units from NORD includes drives for mixing and agitation processes. By equipping the compact and robust MAXXDRIVE industrial gear unit with reinforced bearing and flange versions (VL2/KL2 – VL6/KL6), the drive can be optimally adjusted to application loads.

Seal-less IEC/NEMA adapters (SAFOMI) and a TRUE DRYWELL sealing at the output shaft allow for highest possible operational reliability. The entire drive system – from NORD electric motors to flange connections – is delivered as a ready-to-install unit, which can easily be mounted vertically on the application.

Networked maintenance concepts

NORD also offers innovative predictive maintenance concepts specially designed for MAXXDRIVE industrial gear units. The NORD frequency inverter is an essential component here. The status data available in the inverter can be communicated to a higher-level control or directly to a safe cloud.

The inverter can also directly record external sensor data for vibration monitoring or for measuring the gear unit’s oil sump temperature. Changes to the system condition can be detected at an early stage (condition monitoring) and predictive maintenance can be scheduled in good time.

Vision-based inspection system prevents stock losses

Posted on by David Priestman

A vision-based inspection system designed by AMH Material Handling and developed and installed by Bytronic has brought significant benefits to a major international garment retailer garment conveyor.

AMH Material Handling specialises in the design, installation and integration of automated conveyor and sortation systems for some of the UK’s largest retailers. Since its formation in 2015, the company has quickly become the ‘go-to’ provider for profitable ecommerce and warehouse automation solutions.

It has particular expertise in garment on hanger (GOH) conveyor lines, and it was in connection with this that its engineering team approached Bytronic. AMH wanted to develop a partnership that would help create a new and specialist solution for a major off-price fashion retailer.

The challenge was to create an automated ‘vision-based’ inspection system for the fashion retailer’s GOH conveyors. These conveyors transport up to 140 hanging garments per minute and to work effectively, the solution would have to capture data and process it within milliseconds.

The GOH conveyors developed by AMH Material Handling process millions of garments every year. Overhead GOH conveyors can be designed to transport either single units for sortation or ratio packs and batches for transportation and storage.

Transporting hanging garment ratio packs or batches using GOH conveyors requires separation into single units for accurate sortation. The high-speed separation process can often result in the accidental doubling up of hangers which can often be missed by older item detection technologies.

Over time, the doubling up of hangers can result in stock management issues as the stock information for dispatched items will be incorrect when compared against the stock received at the final destination. For major retailers, this can be a huge problem. To address it, full-time operators were placed on the lines to spot double hanger issues – a costly and labour-intensive fix.

When AMH began developing its bespoke automated solution in 2015, it contacted the manufacturer Cognex and its partner network to supply the machine vision expertise. As one of Cognex’s only UK Platinum Partners, Bytronic was recommended to develop and install the vision solution.

The result is AMH’s vision detection system which identifies double hangers as they pass along the automated single unit sortation line. This solution prevents stock losses without the need for manual checks.

The system combines AMH’s mechanical and electrical installation supported by programmable logic controllers (PLC), Cognex’s cameras and Bytronic’s lighting and vision software programming. The line is able to count each carrier, identify its unique number, track its location, check it is secure and not broken, and identify any double hangers, accepting or rejecting the carrier accordingly.

Bytronic installed and programmed the camera software to capture an image of each carrier when triggered by the line. The camera is detecting several key features including the condition of the carrier and its individual parts to ensure they are maintained and serviced when required to prolong the lifespan of the system.

The image is captured, data processed and an ‘accept’ or ‘reject’ message is sent back to the control system, all within milliseconds. If a doubled hanger or damaged carrier is detected, the ‘reject’ message activates a reject divert, sending the items to a separate defect lane for further inspection.

Managed by AMH, the project was delivered in partnership, with the data captured by Bytronic’s camera and the lighting system being processed by the PLC controls and software solution provided by AMH. The inspection system was calibrated and tested offline before installation, as all factory acceptance testing (FAT) could be done off-site.

Once operational, the savings were immediate. The upgrade has delivered a return on investment in under a year, through significantly reducing operator costs. This meant the ‘inspection’ operators, who were previously on shift 24/6, could now be deployed elsewhere. In addition, the new overhead system has supported a reduction in stock losses by improving both the stock accuracy and inventory being distributed to stores nationwide.

Whilst the project’s primary focus was to detect double hangers, it has delivered a further benefit in identifying possible maintenance issues. The solution now identifies and stores statistics on carrier damage – ready for maintenance engineers to fix and update the system. By removing doubled or damaged hangers from service, it also reduces the risk of tangled hangers and unnecessary downtime due to reoccurring damage.

Barry Pemberton, Solutions Director, AMH Material Handling, said: “We approached Bytronic to help deliver this AMH Material Handling-led solution with us for one of our largest customers. We worked closely together to identify what data the system needed to generate, and how we needed it presenting. From our conversations with Cognex we realised the success of this project would be in the installation of the lighting and vision software, and that’s why we chose Bytronic.”

Asda pioneers use of ‘smart sorting robots’

Posted on by David Priestman

Geek+, a global leader in robotic automation solutions, has collaborated successfully with Asda Logistics Services (ALS) and AMH Material Handling to launch an intelligent sorting system in Asda’s distribution centre. The system will provide Asda with the capacity to support continued growth across its parcel collection and returns business.

Sixty robots have been placed into the supermarket’s South Elmsall, West Yorkshire distribution centre, allowing 2,000 parcels to be sorted each hour with 99.99% accuracy through its Asda toyou service.

The installation marks the first time the technology has been used in this way in the UK, supporting an increase in capacity for Asda toyou’s services as demand for parcel collection and returns services has grown at pace in the last 12 months. With the pandemic causing a change in customer behaviour and an uplift in the number of purchases made online, Asda toyou experienced significant growth through the provision of a reliable, convenient returns solution that allowed shoppers to combine activities in a single trip to an Asda store.

At the same time, Asda toyou has expanded the number of retailers it supports. Over 100 are now available via the service, which has seen it process 65% more returns than at the start of 2020.

The project was implemented by AMH Material Handling, a top provider of material handling solutions, and Geek+. By integrating S20C robots into the existing ALS sorting system, it has provided Asda toyou the ability to respond to rapid changes in order volume and continue to provide excellent services during periods of peak demand.

Lit Fung, VP and Managing Director of Geek+ APAC, UK and Americas, says: “We’re proud to see AMH leverage our sorting system to support a leading retailer like Asda with the flexibility and efficiency needed to expand its Asda toyou business. The process for intelligent sorting is pretty straightforward. By letting a network of AMRs transfer incoming parcels from workstations to cages of corresponding destinations, we can improve accuracy and efficiency while also making the process more ergonomic for warehouse employees. With no need for fixed platform development, it makes it easy for Asda to scale operations in line with business growth. All they have to do is adjust the number of robots and destination chutes.”

Adrian Carter, Sales Director at AMH Material Handling, says: “We had a lot of fun delivering the solution as Geek+ sorting robots are a highly flexible technology that can be integrated and customized to work with existing equipment on customer sites, such as conveyor belts or other robots. It provides us a powerful tool for optimizing sorting operations according to the specific needs of each customer. And, as an integrator, AI-enabled robotics solutions add a new dimension to our services as it allows us to continuously support our customers according to changes in business needs.”

Jon Parry, Vice President of Asda Logistics Services (ALS) at Asda, says: “We’re pleased to be one of the first retailers in the UK to pioneer the Geek+ S20C robots in our National Sortation Centre working in collaboration with partners at Geek+ and AMH.  The robots work alongside our colleagues, enabling us to drive greater efficiencies at times of peak demand, which have helped to boost the number of parcels we’re now able to sort through our Asda toyou service.”

Geek+ and AMH started to cooperate in 2019 when AMH recognized Geek+ robotics solutions provided industry-leading technology. Today, the two work closely together to provide clients all over the UK with great automation solutions.

 

 

AGVs a game-changer in logistics optimisation

Posted on by David Priestman

Automation in logistics is no longer a distant dream. It is already a successful reality in a growing number of companies. How automated guided vehicles (AGVs) can effectively optimise warehouse logistics and what the path to an automated material flow can look like was presented digitally by STILL intralogistics experts on April 13th 2021 at Hannover Messe under the central topic of ‘Digital Transformation’.

The best-practice example of the Danish technology group Danfoss clearly shows how the automation of a production warehouse in Tinglev with STILL transport and software systems became a game-changer for the entire production logistics.

The advantages of automated logistics processes have been known for years. However, in the past few months their importance significantly increased. More urgently than ever, digitisation, flexibility, availability and smart, independent warehouse control are on the agenda of many companies. The good news is: “All the prerequisites are at hand – from technologies to investment models to experienced implementation partners,” explains Hubertus Wabnitz, STILL’s Head of Sales Automated Solutions.

Often, the last hurdle on the road to automated processes is the question “How do I tackle it?” Experts such as STILL, with a broad portfolio of AGVs, intelligent software applications, many years of expertise and a high level of professional consulting skills, are now in demand as partners to help companies on their way to efficient, optimised logistics processes.

STILL has been implementing customised automation solutions for customers for several years on the basis of comprehensive consulting. “Consulting is crucial in order to analyse the automation potential of the customer’s existing logistics together with the customer, to define a reasonable level of automation and to develop a technical basis for an automation concept,” explains Wabnitz.

Intelligent technology optimises logistics processes

Where AGVs ensure a smooth flow of materials, both among themselves and in an optimal interaction with manually operated vehicles, companies benefit in many ways. “Production capacities can be massively increased and reliably planned, regardless of the time of day or the lack of skilled workers. Costs can be optimised and ultimately reduced, due to their complete transparency of processes and reliability, among other things,” says Wabnitz.

In combination with a variety of acquisition and leasing options, automation projects thus become investments that quickly pay off for companies. The risk of transport damage and accidents decreases rapidly while employee safety and the quality of work are improved.

Automation as a success factor

One example of how automated transport systems can become a game changer and optimise entire production chains is the intralogistics project that STILL successfully implemented in Tinglev, Denmark. The aim of the Danfoss technology group was to increase capacity by merging different external warehouses with an automated storage system. Also, the warehouse should be set up flexibly for the requirements of the future. In addition to increasing capacity and scalability, time savings, space optimisation and process harmonisation were decisive goals.

After an extensive consultation and planning phase, STILL implemented a perfectly coordinated combination of six automated series industrial trucks (three MX-X order picking stacker trucks and three EXV high lift pallet trucks) at Danfoss, including all system components.

“In line with current production and material requirements, the warehouse was divided into a fully-automated area with narrow aisles and a semi-automated area with more space for manual order picking,” explains Wabnitz. “Peaks in orders can be responded to flexibly with an increase in vehicles.”

The Tinglev warehouse is a true benchmark project: Danfoss is currently building a modern distribution centre in Rødekro using the same technology by STILL. It is designed for the automated operation of twelve MX-X order picking stacker trucks and five EXV high lift pallet trucks.

Smart technologies for control, optimisation and safety

All AGVs are equipped with the so-called standardised iGo systems automation kit. A modular technology that is almost the same for all applications. The AGVs are manufactured in the same factories as the manual series vehicles. As most components are similar, it is possible to equip the series production vehicles with a so-called automation interface onto which the automation modules can be plugged.

In order for the trucks to be able to move independently throughout the warehouse area, various navigation technologies work together. With STILL iGo insights and the additionally integrated ELOshield safety system, driverless transport logistics at Danfoss is also equipped with two further innovative technologies. With iGo insights, STILL offers an AI-based tool that filters out correlations from the wealth of process information collected in the cloud so that specific recommendations for action can be derived.

This enables Danfoss to further optimise the availability and performance efficiency of the system. The intelligent tool uses the principle of machine learning to improve system performance. All data collected by the control system over a longer period of time is uploaded to the cloud for evaluation and can be accessed online at any time via the encrypted web portal.

The ELOshield system consists of several components that communicate with each other via radio and together form the all-in-one warning system. If an automated industrial truck encounters a pedestrian, the permanently installed module detects the approaching vehicle. A visual and acoustic signal is given. In case of danger, the truck is even slowed down. Each truck is automatically assigned a speed adjustment when entering and leaving the aisles. AGVs are not allowed to enter aisles where picking is taking place.

Shaping the future together

The customer is already very satisfied with the automated warehouse. “An initial analysis already showed cost savings of around 20%,” states Martin Jessen, Production Supervisor at the Danfoss warehouse in Tiglev.

In addition, considerable time savings have been achieved, with deliveries to production every three hours, five days a week. “With full service leasing, we also always keep an eye on the warehousing costs for the next six years,” he adds. Another project with STILL as automation partner is already being planned.

Subscribe

Get notified about New Episodes of our Podcast, New Magazine Issues and stay updated with our Weekly Newsletter.