MiR500 mobile robot helps Cabka automate pallet transport


Germany-based Cabka Group recycles post-industrial plastics into pallets and other material handling products. Cabka North America’ 400,000-square-foot plant in the St. Louis, Missouri area runs 24/7 to manufacture about 5,000 pallets per day.

But Cabka is challenged by labor shortages due to high turnover of temporary workers, which leads to expensive downtime. At Cabka North America’s facility, workers at eleven injection molding machines unload plastic pallets and manually trim and stack them for material handlers to transport to the warehouse using fork trucks or pallet jacks. The work is repetitive and physical, making it hard to retain workers, and the presence of fork trucks on the production floor leads to safety concerns.

However, a new, fully automated production line that will be replicated throughout the facility is helping minimize dependency on temporary workers while also improving product quality and worker safety.

A Mobile Industrial Robots MiR500 autonomous mobile robot is part of that fully automated production line. The production line also includes a Krauss Maffei six-axis robot to autonomously unload pallets from the injection molding machine, trim the pallets, and load the finished products directly onto the MiR500. The MiR500, which is equipped with a MiR pallet lift, transports the finished products out of the manufacturing floor to a separate staging area as soon as the job is complete.

In the staging area, the pallets can be checked for quality and wrapped. Fork trucks then transport the finished pallets to the warehouse and loading docks without having manufacturing workers present. This will allow Cabka to eliminate fork truck traffic in the production area, replacing them with safe, collaborative mobile robots.

MiR500

Cabka North America uses a MiR500 autonomous mobile robot to transport plastic pallets. | Credit: Mobile Industrial Robots

Pilot project leads to fully optimized production

The fully automated production line is intended to be the model for the eventual automation of all eleven production lines, with a fleet of MiR robots supporting them in a dynamic, highly efficient manufacturing floor. Each AMR can go where it’s needed when it’s needed to keep production flowing.

Cabka estimates the first MiR500 travels about three miles a day supporting one production line. With eleven lines planned for autonomous material transport with multiple MiR robots, workers and fork truck drivers will be relieved from many miles of manual material handling, allowing Cabka to redeploy those workers to higher-value tasks.

“With the MiR500, we are very happy with the payload,” said Cabka project technician Craig Bossler. “It’s handled everything that we can stack on top of it. We haven’t found out how high we can go yet. It’s very stable — it can make turns, go straight, and it can hit bumps, and it’s always very stable. The MiR definitely can handle all the imperfections in the floor.”

MiR500

Production of MiR5000 autonomous mobile robots. The company says 40 percent of its sales has gone to the U.S. | Credit: Mobile Industrial Robots

Adding more MiR500 mobile robots

Cabka North America is looking at other ways to use the MiR robots, including prepping orders overnight in the warehouse so they will be ready at the dock for loading in the morning. Patrick Garin, president of Cabka North America, anticipates that other Cabka locations will be following the North American facility’s lead.

“We always have our corporate people come here – our corporate CEO and the other part of the team – and they will definitely be very interested in seeing our progress here,” he said.

Teradyne Inc. of North Reading, Mass., recently acquired Mobile Industrial Robots of Odense, Denmark. Three years ago, Teradyne also purchased another Danish automation company, collaborative robot maker Universal Robots.

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Toolcraft turns to UR e-Series cobots to save on production, increase throughput

Toolcraft Inc., a small precision machining shop in Seattle, makes parts for industries including aerospace, defense, and medical. It needed help tending its CNC machine and ultimately turned to Universal Robots A/S’s e-Series collaborative robots.

Faced with labor shortages and a demanding manufacturing task, Toolcraft assessed its alternatives and worked with an integrator to apply a UR5e cobot to its process.

Challenge

Toolcraft needed to automate a three-step task to keep up with production demands, especially when a large medical device required it to add a third shift for round-the-clock operations. Finding workers is difficult in a region with 3% unemployment.

UR5e Toolcraft case study

“Nobody wants to run on third shift around here,” said Steve Wittenberg, director of operations at Toolcraft. “When you put an ad out, you’re not getting very many responses.”

The company initially looked at traditional industrial robots but realized that it would have to add costly safety infrastructure.

“If we looked at just the robot hardware alone, that appeared to be a more cost-effective solution,” Wittenberg said. “But once we started factoring in the savings on not having to erect a safety cage – and the time saved on the ease of use, avoiding a lot of complex programming – Universal Robots ended up being the right solution.”

Solution

Toolcraft discussed its need for loading a medical device part into a CNC machine for multi-threading with Rapid Design Solutions, a certified systems integrator for UR cobots.

“When we heard that the repeatability of the UR5e was down to 30 microns, we were very excited,” said Troy Ojalehto, owner of Rapid Design Solutions. “That really competes in the same space as traditional industrial robots, so that was huge for us. I have not seen other cobots handling this level of precision with multi-op parts like this, with raw stock going in and completed precision parts coming out.”

Thanks to its force-feedback feature, the UR5e is able to make the part fit tightly in the CNC fixturing. “Using the force motion with freedom in the X,Y and rotational Z axes, we can force the part in there, and wiggle it, and program that compliance very easily to enable basically a human touch with the robot,” he said.

The UR+ program, which certifies that accessories such as grippers, vision systems, and software will work with UR cobots, helped speed up integration.

“For this application, we chose a Pneu-Connect pneumatic gripper,” said Ojalehtos. “A big factor is that it’s UR+ certified, which means it works with Universal right out of the box, with all gripper software integrated directly on the UR teach pendant, eliminating the need to do any script coding.”

PneuConnect gripper at Toolcraft

Toolcraft chose the UR+ certified PneuConnect gripper, which works seamlessly with UR’s teach pendant. Source: Universal Robotics

Results at Toolcraft

“Some of the benefits we’ve seen right off were a significant production increase,” said Wittenberg. “We were able to staff that third shift and went from producing 255 parts a week to 370 parts per week. Along with that, we’re able to finish our year’s production seven weeks sooner, thus freeing up that machine to produce parts on other jobs.”

After six months, Toolcraft saw costs decline by 23%, and it now expects a return on investment on the cobot arm at about 12 months.

“We’re going to be able to be more competitive on a lot of the long-term work that we have,” Wittenberg said.

Since the UR5e cobot only tends parts for six minutes out of a 56-minute cycle, a Toolcraft engineer added a part rinsing and cleaning station after using Universal Robots‘ online training.

“After our automation engineer took the online UR Academy, he spent a few hours with the integrator and was able to add that station to the cobot cycle with no external help otherwise,” said Wittenberg. Universal Robots’ simulator also allowed Toolcraft to program most of the additional tasks without taking the cobot offline.

Toolcraft worked with integratos

After certified systems integrator Troy Ojalehto (right) developed the initial application, Toolcraft automation engineer Brian Laulainen (left) was able to handle daily operations and build add-ons for the UR5e after training through the UR Academy. Source: Universal Robots

In addition, the company was easily able to use Universal Robots‘ I/O interfaces to control the pneumatic fixture and door actuators. “This greatly reduces the need for CNC wiring and preserves all the CNC’s standard safety functions,” Ojalehto said.

The installation has been so successful that Toolcraft is planning to install one cobot every year. “The fact that our own automation engineer is now able to go in and troubleshoot anything that comes up is going to be key in us meeting this goal,” Wittenberg said.

Toolcraft plans to automate tending a horizontal mill next. “That’s a potential challenge because of the mills using rotary tombstones that are swapped in and out of the milling machine, which creates some difficulties with fixturing,” said Wittenberg. “But we’re confident we can solve those using a Universal Robot and some innovation in fixturing.”

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AMP Robotics announces largest deployment of AI-guided recycling robots

AMP Robotics announces largest deployment of AI-guided recycling robots

AMP robotics deployment at SSR in Florida. Source: Business Wire

DENVER — AMP Robotics Corp., a pioneer in artificial intelligence and robotics for the recycling industry, today announced the further expansion of AI guided robots for recycling municipal solid waste at Single Stream Recyclers LLC. This follows Single Stream Recyclers’ recent unveiling of its first installation of AMP systems at its state-of-the-art material recovery facility in Florida, the first of its kind in the state.

Single Stream Recyclers (SSR) currently operates six AMP Cortex single-robot systems at its 100,000 square-foot facility in Sarasota. The latest deployment will add another four AMP Cortex dual-robot systems (DRS), bringing the total deployment to 14 robots. The AMP Cortex DRS uses two high-speed precision robots that sort, pick, and place materials. The robots are installed on a number of different sorting lines throughout the facility and will process plastics, cartons, paper, cardboard, metals, and other materials.

“Robots are the future of the recycling industry,” said John Hansen co-owner of SSR. “Our investment with AMP is vital to our goal of creating the most efficient recycling operation possible, while producing the highest value commodities for resale.”

“AMP’s robots are highly reliable and can consistently pick 70-80 items a minute as needed, twice as fast as humanly possible and with greater accuracy,” added Eric Konik co-owner of SSR. “This will help us lower cost, remove contamination, increase the purity of our commodity bales, divert waste from the landfill, and increase overall recycling rates.”

AMP Neuron AI guides materials sorting

The AMP Cortex robots are guided by the AMP Neuron AI platform to perform tasks. AMP Neuron applies computer vision and machine learning to recognize different colors, textures, shapes, sizes, and patterns to identify material characteristics.

Exact down to what brand a package is, the system transforms millions of images into data, directing the robots to pick and place targeted material for recycling. The AI platform digitizes the material stream, capturing data on what goes in and out, so informed decisions can be made about operations.

“SSR has built a world-class facility that sets the bar for modern recycling. John, Eric and their team are at the forefront of their industry and we are grateful to be a part of their plans,” said Matanya Horowitz, CEO of AMP Robotics. “SSR represents the most comprehensive application of AI and robotics in the recycling industry, a major milestone not only for us, but for the advancement of the circular economy.”

The new systems will be installed this summer. Upon completion, AMP’s installation at SSR is believed to be the single largest application of AI guided robots for recycling in the United States and likely the world. In addition to Florida, AMP has installations at numerous facilities across the country including California, Colorado, Indiana, Minnesota, and Wisconsin; with many more planned. Earlier this spring, AMP expanded globally by partnering with Ryohshin Ltd. to bring robotic recycling to Japan.

About AMP Robotics

AMP Robotics is transforming the economics of recycling with AI-guided robots. The company’s high-performance industrial robotics system, AMP Cortex, precisely automates the identification, sorting, and processing of material streams to extract maximum value for businesses that recycle municipal solid waste, e-waste and construction and demolition.

The AMP Neuron AI platform operates AMP Cortex using advanced computer vision and machine learning to continuously train itself by processing millions of material images within an ever-expanding neural network that experientially adapts to changes in a facility’s material stream.

About Single Stream Recyclers

Single Stream Recyclers is a materials recovery facility in Sarasota, Fla. It processes, materials from all over the west coast of Florida. The facility sorts, bales and ships aluminum, cardboard, food and beverage cartons, glass, paper, plastics, metal and other recyclables from residential curbside and commercial recycling collection. SSR is heavily invested in technology to help create the best possible end products and reduce contamination as well as residue.

Techmetics introduces robot fleet to U.S. hotels and hospitals

Fleets of autonomous mobile robots have been growing in warehouses and the service industry. Singapore-based Techmetics has entered the U.S. market with ambitions to supply multiple markets, which it already does overseas.

The company last month launched two new lines of autonomous mobile robots. The Techi Butler is designed to serve hotel guests or hospital patients by interacting with them via a touchscreen or smartphone. It can deliver packages, room-service orders, and linens and towels.

The Techi Cart is intended to serve back-of-house services such as laundry rooms, kitchens, and housekeeping departments.

“Techmetics serves 10 different applications, including manufacturing, casinos, and small and midsize businesses,” said Mathan Muthupillai, founder and CEO of Techmetics. “We’re starting with just two in the U.S. — hospitality and healthcare.”

Building a base

Muthupillai founded Techmetics in Singapore in 2012. “We spent the first three years on research and development,” he told The Robot Report. “By the end of 2014, we started sending out solutions.”

“The R&D team didn’t just start with product development,” recalled Muthupillai. “We started with finding clients first, identified their pain points and expectations, and got feedback on what they needed.”

“A lot of other companies make a robotic base, but then they have to build a payload solution,” he said. “We started with a good robot base that we found and added our body, software layer, and interfaces. We didn’t want to build autonomous navigation from scratch.”

“Now, we’re just getting components — lasers, sensors, motors — and building everything ourselves,” he explained. “The navigation and flow-management software are created in-house. We’ve created our own proprietary software.”

“We have a range of products, all of which use 2-D SLAM [simultaneous localization and mapping], autonomous navigation, and many safety sensors,” Muthupillai added. “They come with three lasers — two vertical and one horizontal for path planning. We’re working on a 3-D-based navigation solution.”

“Our robots are based on ROS [the Robot Operating System],” said Muthupillai. “We’ve created a unique solution that comes with third-party interfaces.”

Techmetics offers multiple robot models for different industries.

Source: Techmetics

Techmetics payloads vary

The payload capacity of Techmetics’ robots depends on the application and accessories and ranges from 250 to 550 lb. (120 to 250 kg).

“The payload and software are based on the behavior patterns in an industry,” said Muthupillai. “In manufacturing or warehousing, people are used to working around robots, but in the service sector, there are new people all the time. The robot must respond to them — they may stay in its path or try to stop it.”

“When we started this company, there were few mobile robots for the manufacturing industry. They looked industrial and had relatively few safety features because they weren’t near people,” he said. “We changed the form factor for hospitality to be good-looking and safer.”

“When we talk with hotels about the Butler robots, they needed something that could go to multiple rooms,” Muthupillai explained. “Usually, staffers take two to three items in a single trip, so if a robot went to only one room and then returned, that would be a waste of time. Our robots have three compartment levels based on this feedback.”

Elevators posed a challenge for the Techi Butler and Techi Cart — not just for interoperability, but also for human-machine interaction, he said.

“Again, people working with robots didn’t share elevators with robots, but in hospitals and hotels, the robot needs to complete its job alongside people,” Muthupillai said. “After three years, we’re still modifying or adding functionalities, and the robots can take an elevator or go across to different buildings.”

“We’re not currently focusing on the supply chain industry, but we will license and launch the base into the market so that third parties can create their own solutions,” he said.

Techmetics' Techi Cart transports linens

Techi Cart transports linens and towels in a hotel or hospital. Source: Techmetics

Differentiators for Techi Butler and Cart

“We provide 10 robot models for four industries — no single company is a competitor for all our markets,” said Muthupillai. “We have three key differentiators.”

“First, customers can engage one vendor for multiple needs, and all of our robots can interact with one another,” he said. “Second, we talk with our clients and are always open to customization — for example, about compartment size — that other’s can’t do.”

“Third, we work across industries and can share our advantages across them,” Muthupillai claimed. “Since we already work with the healthcare industry, we already comply with safety and other regulations.”

“In hospitals or hotels, it’s not just about delivering a product from one point to another,” he said. “We’re adding camera and voice-recognition capabilities. If a robot sees a person who’s lost, it can help them.”

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Distribution and expansion

Techmetics’ mobile robots are manufactured in Thailand. According to Muthupillai, 80% of its robots are deployed in hotels and hospitals, and 20% are in manufacturing. The company already has distributors in Australia, Taiwan, and Thailand, and it is leveraging existing international clients for its expansion.

“We have many corporate clients in Singapore,” Muthupillai said. “The Las Vegas Sands Singapore has deployed 10 robots, and their headquarters in Las Vegas is considering deploying our products.”

“Also, U.K.-based Yotel has two hotels in Singapore, and its London branch is also interested,” he added. “The Miami Yotel is already using our robots, and soon they will be in San Francisco.”

Techmetics has three models for customers to choose from. The first is outright purchase, and the second is a two- or three-year lease. “The third model is innovative — they can try the robots from three to six months or one year and then buy,” Muthupillai said.

Muthupillai said he has moved to Techmetics’ branch office in the U.S. to manage its expansion. “We’ll be doing direct marketing in California, and we’re in the process of identifying partners, especially on the East Coast.”

“Only the theme, colors, or logos changed. No special modifications were necessary for the U.S. market,” he said. “We followed safety regulations overseas, but they were tied to U.S. regulations.”

“We will target the retail industry with a robot concierge, probably by the end of this year,” said Muthupillai. “We will eventually offer all 10 models in the U.S.”

Chinese mobile robot maker Geek+ coming to America

Chinese artificial intelligence and robot maker Geek+ (Beijing Geekplus Technology) will be demonstrating its line of picking, moving and sortation robots April 9-12 in Atlanta, GA at MODEX, the largest supply-chain trade show in the Americas. Geek+ is a leading provider — and China’s #1 supplier — of warehousing and logistics solutions in China and…

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Quiet inroads in robotics: the Vecna story

Robotics is undergoing fundamental change in three core areas: collaboration, autonomous mobility and increasing intelligence. Autonomous mobility technology is entering the industrial vehicle marketplace of AGVs, forklifts and tugs with new products, better navigation technologies and lower costs. Forecasters Grandview Research and IDTechEx suggest that autonomous forklifts and tugs will emerge as the standard from…

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