Study of an Autonomous Forklift for Warehouse Operations

INTRODUCTION-

Every company looks for ways to improve efficiency, lower costs,?and streamline operations.?Finding ways to automate?repetitive tasks is often the easiest way to accomplish all these things at once.??There are several reasons why automation in logistics is booming these days. First of all, there is a forklift driver shortage: it is difficult to find skilled people to operate a forklift. Secondly, the operational cost of automation is more often lower than manual operation. Thirdly: this era of e-commerce requires a need for streamlined delivery, which forces logistics providers to plan and predict their logistics flow more consistently to achieve next-day delivery. Further, an automated truck drives the route as it is programmed, not damaging the infrastructure or the load, or causing any injuries, which is essential. Along with that, in terms of environment-friendliness, an AGV also uses less energy and wears less quickly.

The strength of automated forklift trucks is that they are good at being repetitive and seeing patterns in large amounts of data, but they need precise instructions to create value. Humans on the other hand, are good at understanding context and adapting to new environments, but they sometimes get tired and lose focus. So the best solution is to have people and machines work together to a certain extent, to get the best of both worlds.

WHERE TO START WITH AUTOMATION? -?

In the logistics industry, automation might not be the answer for every logistics flow. It all comes down to eliminating waste (zero Muda) and adding value where it makes the most sense.

When it comes to automated solutions, the trend in the European market is changing: there is a bigger demand than supply, and it’s increasing even more. Configurable standardized automation packages can help customers with automation needs to reach their targets quicker.

An automation journey for customers consists of 3 steps. First, the supplier needs to understand your business, the logistics flow on your site, and your main challenges. The second step is the optimization phase since you don’t want to “automate the fat” as we call it. Here your processes will first be optimized before starting automation, according to the Kaizen philosophy (continuous improvement). Finally, there is the realization: every customer is unique, but everyone should be provided with the best possible solution: the combination of benefits between man and machine.?

HOW AUTONOMOUS FORKLIFTS WORK-

The robotic lift truck uses similar hardware and technology used in self-driving vehicles to turn a standard model into an autonomous vehicle;?Light Detection and Ranging (LiDAR).

LiDAR is defined as a surveying method that measures the distance to a target by illuminating the target with?laser light and measuring the reflected light with a sensor.

Thus, the robotic lift truck compares in real-time, what it sees with the reference map it is programmed to and navigates with accuracy.?

Robotic Laser Mapping

The ability of RLT’s to run with zero, partial or full interface with?warehouse management systems (WMS)?allows for a fast startup with little infrastructure modification, provides tracking of load movement and enables informed management decisions.?

Most warehouses aren’t ready to spend seven figures on a fully built and programmed complex RLT application and we get that.

So, in this instance, we suggest you consider scaling your operations.

One option is to begin with one RLT and keep the process simple.

An example of this is an operator unloading a trailer and having an AGV pick up the load and drive it to the rack where another operator will pick the load and put it away.

Later on, you can upgrade this as your application grows and you become more comfortable with how RLT’s coincide with your warehouse.??

RLT’s are broken down into two different categories:

1.???Basic Applications

2.???Complex Applications

Basic applications require one or two simple tasks, whereas complex applications will ask the lift truck to perform multiple tasks.?

Robotic Forklift Basic?Applications

1. Location Scanning

The?RLT’s scanning technology?enables it to check the availability of locations in?a floor storage area.

Using the laser on the front of the truck, the RLT can scan several loading bays, detect free locations and place a load there.?

2. Dock Staging and Put Away

Transports loads to shipping docks from receiving docks to storage.

This process moves loads from docking areas directly to the?programmed storage area?and returns to grab another load.?

Robotic Forklift Complex Applications

1. Machine Interfacing

Drop off and pick up loads from production lines, workstations or storage areas.

The robotic lift truck will also transfer materials or goods between production cells.

2. Conveyor Interfacing

The RTL will interface with your infrastructure, whether that is smart conveyors, automatic wrapping machines, stacker cranes, robotic palletizer, etc. moving loads from one station to the next.?

3. Bar Code Scanning

An optional barcode reader can be added to your robotic lift truck, allowing for products to be tracked through the factory or warehouse.

The barcode reader triggers a transport order as soon as the RTL picks up the pallet to deliver it to the programmed location.

The RTL transmits the load information by interfacing the WMS or ERP.

4. Logistics Trains

Logistics trains allow transportation of multiple carts hauled by an RLT.

When the operator signals the ERP/WMS, the RLT moves to the station, where the operator retrieves what they need.

Pressing a button on the RLT touch screen sends it to its next destination.?

5. Machine to Storage & Storage to Retrieval

RLT’s enable dependable storage of loads up to 6.56 feet high (in very narrow aisles).

RLT’s can help reduce product damage by controlling speed, acceleration, and controlled stops.

Whether your application is a warehouse, floor or buffer storage the scalable range of RLT’s can help meet application demands while reducing opportunities for accidents caused by operator error or misuse of equipment.?

PARTS OF AUTOMATED FORKLIFTS-

1. Navigation

Automated forklift works with all established navigation technologies. There is support for a combination of technologies, so-called multi-navigation, which is good if you want to serve a storage space using one type of navigation and a production area using another.

Natural

Reflector

Barcode

Spot

Magnetic Tape

Inductive Wire

Multi-navigation

2. Natural Navigation

Automated forklift with natural navigation lets AGVs use objects in the existing environment for navigation, removing the need to install reflectors and markers. This cuts down on installation time, reducing costs and minimizing the effect on operations. Natural navigation also simplifies the expansion of systems.

3. Hardware

Automated forklift hardware consists of powerful and reliable components in a number of areas. All components are designed for tough environments where vibrations, dust, moisture and temperature variations are all part of daily life.

* Encoders, Vehicle I/O and Safety sensors are not part of Kollmorgen offering

4. Software

Automated forklift gives you access to a set of efficient design and service tools. The design tools help you outline all kinds of layouts as well as system and vehicle applications. You also have access to service tools for diagnostics and maintenance.

Automation doesn’t need to be complex: Modular thinking

Automated solutions can seem unique and complex, but the material flow it is actually quite logically and systematically moved throughout the site. With a systematic approach you can easily find commonly used functions that could be described into configurable modules for repetitive use. This is the Toyota way of working: separating the repetitive parts from the unique, one-of-a-kind, within the process.

Let’s take a closer look. By going to the source (genchi genbutsu) and visiting customer production sites, we can find common elements: inbound docks, material buffers, picking and kitting areas for preparing goods, production area, final goods storage, and the outbound area. As the material flows through the site, it passes these main?processes:

• Put-away: moving incoming goods to the material buffer
• Replenishment: feeding material to production
• Return handling: such as empty pallets, scrap
• Point-to-point transport: within the production areas
• Finished goods: taking finished goods to a temporary storage and then to the outbound area for shipping