FEATURE Automated warehousing
Robots in the warehouse By Anson Yeganegi, Director of System Solutions, TDK I
ntegrating robotics in warehouse, distribution and industrial settings has revolutionised manufacturing processes, logistics and operational
effi ciency. From traditional industrial robots to the latest advancements in mobile robots, bipedal robots and air ones (drones), the industry is witnessing a major move to automation for enhanced effi ciency and productivity.
Industrial robots Industrial robots have a long-standing history in various sectors, most notably in automotive manufacturing and warehouse operations. Their speed, precision movement, effi ciency and ability to perform repetitive tasks make them indispensable. Often working in isolation, away from human interaction, they can perform in harsh environments, handle hazardous materials and tasks. To achieve precision in movement at a fast pace, industrial robots rely on an array of sensors, including angle, motion, temperature and pressure, and embedded motor controllers. Additionally, their capacity for data collection on production processes and quality control elevates their role in ensuring repeatability and quality assurance. However, industrial robots come with a set of challenges: Their programming complexity requires specialised skills for training and maintenance. The high initial installation costs can be substantial barriers in some industries. Limited adaptability, potential malfunctions leading to downtime costs, and spatial restrictions requiring meticulous planning for deployment pose additional
32 March 2024 | Automation
considerations. While industrial robots have traditionally been the workhorse in manufacturing and warehouse settings, we are now increasingly seeing the adoption of cobots in these environments. Cobots rely on rechargeable batteries and a host of additional sensors to perform tasks and navigate around.
Mobile robots
Automated guided vehicles (AGVs) in their simplest form have played a pivotal role in the transportation of parts in the automotive industry since the 1950s. Essentially functioning as robotic carts, they follow predetermined routes delineated by magnetic tape, wires and visible markings in the warehouse or the factory fl oor. The ‘smarter’ AGVs use LiDAR to avoid obstacles, making them practical for warehouse settings. The next-generation AGVs, called autonomous mobile robots (AMRs), use cameras and ultrasonic time-of- fl ight (ToF) sensors to navigate through complex environments. This makes them adaptable and fl exible, with some being fi tted with robotic arms, forklifts and conveyors to handle heavy payloads. Some even perform assembly and inspection tasks.
Game-changing capabilities for AMRs emerged with the introduction of simultaneous localisation and mapping (SLAM) technology, which uses data from LiDAR, cameras and ToF sensors to build a 3D map of the environment to guide the AMR. Also key to AMR capabilities is the onboard inertial measurement unit (IMU), a motion sensor that measures
acceleration, orientation and angular velocity. It provides the AMR with a more accurate estimate of its position and movement. With industrial IoT in the form of 5G connectivity, AMRs can communicate with larger warehouse management systems, enabling route planning based on inventory requirements and orders. With a real-time communications network, the AMRs can also communicate with one another, and with AI and machine learning (ML) they can make swift decisions on the coordination of tasks. This approach, known as swarm autonomy, not only enhances task effi ciency but also introduces redundancy. In previous generations of AMRs, human intervention was required when there was a malfunction or a recharge requirement, resulting in downtime. With swarm autonomy, another AMR can seamlessly assume the assigned task, ensuring uninterrupted operations in the warehouse.
Bipedal robots
In facilities with uneven surfaces, stairs and ladders, the limitations of wheeled robots are self-evident – if they were to tip over or unable to complete their task, they would be out of action, resulting in productivity losses. There’s also collision avoidance to consider – they tend to slow down to manoeuvre around an obstacle, or stop to let others pass, which all adds up to more time, and time is money. That’s when the spotlight turned to bipedal robots. Bipedal robots, with legs and arms designed to mimic human movements,
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