MHD speaks to Glenn Powell, General Manager of Face Consultants on how his company can help make a warehouse run efficiently.
The Australian Government released its first National Robotics Strategy on May 28, 2024, aiming to unlock the benefits of automation and robotics and ‘build a future made in Australia’.
The strategy is based on four themes:
• National Capacity – to support the domestic market and global exportation of Australian robotics and automation.
• Increased Adoption – raising awareness and incentivising businesses to adopt and integrate the new technology into their operations.
• Trust, inclusion and responsible development and use – ensuring safe, secure, and inclusive technologies are used to benefit workers.
• Skills and diversity – support for all Australians from all backgrounds so they can contribute to and benefit from new technologies introduced.
“The government is keen to move the country up the worldwide stage, positioning Australia as a world leader in developing, manufacturing and using responsible robotics and automation technologies,” says Glenn Powell, General Manager of Face Consultants, a company specialising in the design, testing, and surveying of concrete floors for industrial and commercial warehouse facilities.
Robotics, and how they are distributed throughout a warehouse, and their impact on a warehouse floor, are key issues that need to be considered when automating a DC, according to Glenn.
Robotics used in warehouses
“There are many robotics currently being used in warehouses,” says Glenn. “With the most common being Automated Guided Vehicles, also known as AGVs, which follow predefined paths indicated by markers, wires, lasers, or magnets to transport goods around the warehouse.”
Then there are Autonomous Mobile Robots or AMRs, which use sensors and cameras to navigate rather than following a set path. They are frequently used to move inventory, replenish stock, and pick orders.
Another useful tool is stationary, or mobile, robotic arms that are equipped with suction cups or grippers to pick stock from shelves and pack boxes or pallets.
Finally, there are Collaborative Robots, or Cobots, which are robotics designed to work alongside humans to help them when tasks are dangerous, repetitious, or strenuous.
Where it all began
Using robotics for packing, sorting, picking, transportation, and inventory management is now commonplace, but the first practical AGV prototype was developed in the 1950s by the Barrett Electronics Corporation in Illinois, USA.
They used a tow truck to move materials in a warehouse, with the position guided by a wire placed in
the floor.
AGVs were first introduced in Australia in the late 1970s and early 1980s, typically used in manufacturing or logistics sectors.
AMRs appeared in the early 2000s, with companies such as Amazon Robotics (formerly Kiva Systems) playing a significant role.
Early adopters in Australia at this time included retailers, e-commerce, and logistics
“There are multiple benefits to using robotics within warehouses, such as automating repetitive tasks, reducing labour costs and human error, and streamlining order fulfilment [in conjunction with inventory management],” says Glenn.
“AGVs and AMRs increase materials handling and logistics productivity, while robotics such as Cobots work alongside humans to boost flexibility and reduce injury risks.”
Where it is going
New warehouse robotics in 2024 include BionicHive’s Squid Robot. Although developed in 2016, the Squid Robot is just being introduced to the market, offering an automated, autonomous solution for picking and replenishing boxes.
The robots can deliver anywhere within the warehouse, moving across the floor and vertically and horizontally up racks.
LG’s CLOi CarryBot delivers small to medium packages across almost any distance. Designed to deliver items end-to-end using autonomous driving and obstacle avoidance, operators can stay within their assigned zones.
The beauty of the CarryBots is they can integrate with a WMS to create efficient order distribution and scheduling. They can also be programmed to navigate most floor plans, with virtually unlimited pick-up and delivery points.
Agility Robot’s Digit is ‘the most advanced Mobile Manipulation Robot (MMR) on the market’.
A bipedal robot, Digit is designed to grasp and handle items while moving. It can circumnavigate tight spaces and corners and is now being trialled by Amazon to pick up and move empty totes once inventory has been depleted.
Retro-fitting lift trucks with automated systems have been available for some time. However, new dual-mode robotics integrated into existing lift trucks mean they can operate autonomously or manually at the touch of a button. This allows peak performance during busy periods and the ability to revert to manual operations when the warehouse is quieter.
Technologies such as telematics and advanced infrastructure-free navigation systems help to minimise human error and optimise workflows.
Considerations when introducing or upgrading robotics
“Apart from the obvious financial considerations, one of the first, but frequently overlooked areas needing investigation, is the floor of your warehouse or facility,” says Glenn.
A predictable surface means precise movements with no interruptions, and a flat and level floor optimises robotics efficiency, speed, safety, and stability.
With robotics, different characterises are also required. These can include gloss, friction and light reflectivity.
“We are also seeing floors wear differently within defined movement areas and where the robotics turn,” says Glenn.
Floors are literally wearing out, so abrasion resistance is also a key requirement for the long-term performance of an automated solution.
“Flat floors also affect maintenance as they reduce wear and tear and increase the robotics’ lifespan,”
says Glenn.
“Floors are easier to maintain and keep clean, creating less dust and, therefore, less impact on cameras and sensors.”
Where to start
The first step is to contact a company like Face Consultants, who will deliver unbiased results with no vested interest in the outcome.
Using the latest digital floor flatness testing technology is essential, as is agreeing on a clear method of compliance checking.
All stakeholders then understand the factors required to deliver a floor suitable for an efficient and successful automated warehouse, including the working parameters of the robotic equipment.
Surface regularity, flatness, levelness, curvature, step transitions, and abrasion resistance must be considered. So too should surface characteristics such as specified gloss, friction, and micro-roughness requirements.
Once floor testing has been completed and any deviations from specifications identified, then any required floor remediation is
carried out.
CoGri Australia is a specialist in upgrading floors for robotic systems, whether it’s grinding a floor into tolerance or repairing joints or cracks.
If it’s a new project, the floor design is a critical stage. The floors must be designed and constructed in a way that allows robotics to operate at their optimum performance.
After the floor is constructed, or remediation is carried out, a final testing of the completed floor surface must be completed to ensure compliance.
“The world of robotics for warehouses is so exciting right now,” says Glenn.
“But introducing them carries its share of hard decisions, from which type of equipment will benefit your operations, to how best to finance them. The quality of the floor your robotics operate on shouldn’t be one of them. A little due diligence at the start can prevent a world of problems and delays later.”
To read more about CoGri, click here