Pallet Stacking Application: VisionNav Robotics AGV Contributes to Improve Flexibility in Food-processing Company

 

One of the customers that VisionNav served is a well-known food processing company in China, who has international management system, global quality supervision system and strong R&D team and sells products to USA，Canada, Japan, the Middle East and other countries and areas. However, due to the labor shortage in operations, inefficiency of finished good packing and warehousing has always been a long-term headache for the company. To solve the problem and further reduce costs, VisionNav Robotics introduced VNP15 series, counterbalanced stacker type forklift AGVs, as well as the digitalized management system, in order to replace traditional manual operation and realize full automation in logistics processes.

Project Overview

The project includes 2 processes:

1) Finished Goods Packaging: Forklift AGVs pick material from automatic stacker – send packing material to production line – (packing operator) - recycle empty pallets - replenishing empty pallets - transport finished goods to transit area;

2) Storage: Forklift AGV pick finished goods from transfer area and send to FG warehouse – storage by 2 stacks;

Solutions / Products

Part 1: VisionNav Robotics VNP15 Series Counterbalanced AGV

Counterbalanced Stacker Forklift AGV
Model No.	VNP10	VNP15
Lifting Height	0-4000mm	0-4500mm
MAX Loading Capacity	1000KG	1500KG
MINI Stacking Aisle Width	2750mm	3000mm
Weight (with battery)	2200KG	2400KG
Carrier / Goods Type	Nine Block Pallet Four-way Entry Open/Close-boarded Pallet Stillage Cage Roller Cage
Applicable Scenario	Indoor Horizontal Transportation Indoor Production Material Transfer Indoor Put-Away and Picking
Image

 

Part 2: VisionNav Robotics Central Control System

Information such as site forklift AGVs, pallets, goods, equipment will be controlled by central control system. The system issues tasks commands to forklift AGVs to schedule forklift AGVs to execute tasks.

Project Results

By using forklift AGV (multi-series) system, packing material (carton boxes, wrapping films) and finished goods will be unmanned transported among production line, transit area and FG warehouse. The workflows include sending packing material, replenish empty pallets, send finished goods to transit area and send finished goods from transit area to FG warehouse.

 

Project Highlights

1) High Flexibility: not changing original operation processes, site environment and equipment, adaptive to man-machine mixed operations;

2) High Efficiency: system automatically integrates without any manual intervention, forklift AGVs operate with high efficiency which is close to manual operation in peak;

3) High Stability: stack by two layers with high operation stability;

4) Safety: 360° anti-collision avoidance function with 5 level safety protection to ensure the safety of human, vehicles and goods.

 

Project Value

1) Reduce operating costs by replacing 10 operators’ vacancies. The company worked in 2 shifts per day, 5 operators per shift before, now it is unmanned operation all day;

2) Realize digital management by matching the information flow and logistics flow, to help upgrade intelligent manufacturing;

3) Achieve high efficiency with 24/7 unmanned operation, meeting the needs of material supplement, material replenishment and finished goods storage.

 

About VisionNav Robotics

VisionNav Robotics, a global leader in industrial driverless vehicles, is committed to enabling vehicles with driverless technology and promoting flexible unmanned application in logistics. VisionNav Robotics provides industrial driverless vehicle products and flexible unmanned logistics solutions for manufacturing logistics and warehousing logistics. At present, various types of autonomous forklift and tractor products have been developed and produced, realizing applications such as 9.4m high level storage and retrieval, 2.0m narrow passage storage and retrieval, truck loading and unloading, and multi-layer stacking, which are widely used in automobile manufacturing, tire manufacturing, food, petrochemical, e-commerce logistics, third party logistics, pharmaceutical and many other industries.

 

 

Heavy-load AGV: VisionNav Robotics Application in Ceramic Industry

Abstract: Unmanned logistics has been main focus of ceramic industry. This article takes an example of an internationally renowned ceramic company, fully introduces how to introduce heavy-loaded forklift AGV in business processes in terms of project requirements, proposal development and project implementation, and finally realize unmanned logistics and automation in tile production. 

In June 2021, unmanned logistics project jointly created by an internationally renowned ceramic company and VisionNav Robotics has been successfully launched, becoming an excellent example of intelligent logistics upgrading in ceramic industry.

Project Requirements

The company mainly produces ceramic tiles and plates, rock plate and other ceramic products, especially their ceramic plates, which enjoys a high reputation in both domestic and overseas markets. The company owns 3 large production bases, 21 ceramic tile production lines and 4 ceramic plate production lines in China and foreign countries. In recent years, with increasing demand of customization, company is actively looking for opportunities for intelligent upgrad. After several investigations in supplier’s strength, research and development capabilities, product performance and service capabilities, the company choose VisionNav to cooperate in their first unmanned logistics project in ceramic tile production.

In ceramic production, especially for customized tile plates, material is very heavy and fragile, raising high requirements in intra-transportation. Several business processes are involved in this project including material transportation from kiln to semi-finished stereoscopic warehouse, from warehouse to polishing line, which all need to realize unmanned logistics and automation management.

Unmanned Processes

Project Difficulties:

1) Complicated working conditions: working conditions in ceramic tile production area are normally very complicated, mainly are with high concentrations of dust and bad ground flatness. When unmanned facilities are introduced to the scene , man-machine mixing situation also needs to be considered. Therefore, higher requirements for safety and system scheduling ability of driverless vehicles are put forward.

2) Particularity of material: ceramic tiles, especially tile plates, are heavy in weight, large in size and fragile, which is a extremely test in carrying capacity and stability of driverless vehicles;

3) Process requirements: due to the requirement of precise stacking in stereoscopic warehouse, the perception and adaptive control ability of driverless vehicles are highly required. 

Solution and project deployment

After preliminary investigation and site visit, VisionNav Robotics developed an intelligent and replicated solution for internal unmanned logistics based on customer's needs and existing processes. Considering heavy weight of the material, the use of heavy-load driverless forklift VNL45 is proposed, with system integration between VisionNav central control system and customer’s existing business process management system. There is no need to install reflectors or magnetic strips on site, which enhance flexibility and scalability in the project.

 Heavy-Load Pallet Stacker Type Forklift AGF

 

1) System deployment

Customer has already deployed its own WMS system. VisionNav’s central control system (RCS) manage seamless system integration with the existing system to have accurate data.

2) Terminal deployment: Kiln → Semi-Finished Stereoscopic Warehouse → Polishing Line

Material: semi-finished ceramic tiles, 1000~3000Kg

Equipment: heavy load pallet stacker forklift AGV VNL45

Operational Process: Customer system calls forklift AGV via RCS to transport semi-finished products from kiln to stereoscopic warehouse. After 1 day for cooling, AGV will again transport products to polishing line, and return with empty rack.

Highlights: The material rack at customer site is with four-legs bearing type, which needs to be accurately stacked to a fixed position (4 fixed piles) on 1^st level of the rack in the warehouse. VisionNav Robotics’ forklift AGV automatically stacks material rack accurately. With the help of space perception, AGV can improve the accuracy of its operation.

1^st Level of the Rack in the Warehouse

 

Project Outcome

This project achieves unmanned material transportation between production line and semi-finished goods warehouse, effectively replacing manual work and improving operation accuracy, helping peer companies to achieve:

1)     Precise operation: forklift AGVs can work 24/7 to automatically unload, transported and store material, achieving in-time intra-logistics and reducing human operational errors.

2)     Intelligent management: scheduling system can do real-time matching of information flow and logistics flow, achieving the goal of digitalization, automation and intelligent management.

About VisionNav Robotics

VisionNav Robotics（www.visionnav.cn), a global leader in industrial driverless vehicles, is committed to enabling vehicles with technology, promoting flexible unmanned application in logistics. VisionNav Robotics provides industrial driverless vehicle products and flexible unmanned logistics solutions for manufacturing and warehousing logistics. At present, a number of driverless forklift and tractor products have been developed and produced, breaking through rigid demand scenarios such as 9.4m high access, 2.0m narrow channel access, driverless loading and unloading vehicles and multi-layer mobile frame stacking, which are widely used in automobile manufacturing, tire manufacturing, transportation, food, petrochemical, e-commerce logistics, third party logistics, pharmaceutical and other fields.

Major Product Launch! VisionNav Premieres First Counterbalanced Truck Series for Truck Loading and Unloading, Leading Large Scale Application in All Scenarios

 

VisionNav Robotics launched one of their most revolutionary products, VNP20 series automated guided counterbalanced truck. The new product can work indoor and outdoor, and do the truck loading and unloading in loading bay. It can also be used in in all different applications and scenarios.

R&D Background

In the past five years, with experiences from 100 projects and over 500 proposed solutions, VisionNav team realized that industrial driverless vehicle will not have large-scale application unless we can find solutions to solve the most complicated problems such as truck loading and unloading, put away and retrieval from high level racks, pallet stacking, stillage cage staking, etc. The difficulties always come from the complicated and volatile surrounding environment (man-human share paths, disordered placement, non-standard products, variety types of trucks, etc.)

For customers, the only way to know whether industrial driverless vehicles are workable (completely replacing manual trucks) is its peak working efficiency compared to manual trucks in c complicated and volatile surrounding environments. That is, without sacrificing safety and stability, “automated” perception (information acquisition) and motion control (action execution) capabilities shall be infinitely close to "manual".

Technology Implementation

At the end of 2018, VisionNav Robotics kicked off the research and development of VNP20 series. It took 10 doctors nearly three years to develop VNP20 product with strong sense and motion control ability by mixing self-developed 3D laser + visual perception technology, multi-axis real-time motion planning technology and high-precision visual servo control technology. With maximum running speed of 3.0m/s, multi-axis motion, accurate and continuous fork movement, the peak working efficiency of VNP20 can compare to manual truck in complex and changeable environment.

3D Laser + Visual Perception, Visual Servo Control for Better Safety and Efficiency

In forward direction, we use 3D laser + visual perception to greatly increase the perception distance and field of view. The maximum running speed of VNP20 can achive 3.0m/s while the operation is 100% safe. In the meanwhile, with in-depth learning and classification of obstacle targets, it can realize real-time judgment and auto detouring.

In the fork direction, we use 3D laser + vision to generate observations of the target objects and available space for pick and place, which can optimize real-time 6-DOF motion of the forklift AGV, as well as feedback results to visual server controller. These are to realize smooth movement of multi-axis combinations, making sure the accurate and efficient execution of the fork moving during loading and unloading, picking and placing, stacking and destacking, etc.

Equipped with Various Attachments to Standard Truck to Solve Non-Standard Issues

There are various attachments for VNP20 series standard products, such as side shifter, adjustable fork, multi-pallet handler, rotator, paper roll clamp, pipe winder, etc. We have standard control module configured for each type of attachments to meet different requirements for materials handling and transportation in different industries, such as pallets, cages, soft bags, paper rolls, and turnover boxes.

Stronger ground adaptability to cope with loading bay and outdoor working conditions

VNP20 is equipped with 450mm hard-wearing solid rubber wheels to have better obstacle surmounting ability, climbing maximum 13% degree slope, passing over maximum 50mm width grooves and running up maximum 30mm height steps. Now it can easily work in loading bay and outdoor for high-speed, heavy-loaded working conditions.

Starting with Truck loading and Unloading in Loading Bay to Cover All Scenarios

What are the key design of VNP20 series product launched by VisionNav Robotics?

Yang Jianhui, Product Director of VisionNav Robotics, said that during the R&D process, the main focus is on the AGV working ability in complex and changeable surrounding environment, including indoor positioning ability under changing lighting, 3D environment perception ability, accurate and efficient visual servo control ability, and water/dust-proof ability. “Truck loading and unloading operation accounts for more than 50% of the manual truck operations in warehousing logistics, which is the main target application place for VNP20. However, the working condition is highly complicated, not only because the variety of the truck types, parked vehicles everywhere, but also the diverse shapes of the material for loading and unloading, which requires our products to have very strong perception ability. In the meanwhile, truck loading and unloading requires highest peak efficiency in all scenarios, therefore it is also very important to achieve efficient motion by motion optimization and visual servo control.

VNP20 series products also use high-performance hardware, software and configuration from driverless cars to solve technical problems for complex scenarios such as truck loading and unloading, helping to build a solid foundation to realize large-scale application of industrial driverless vehicles in whole scenarios.

About VisionNav Robotics

VisionNav Robotics（www.visionnav.com), a global leader in industrial driverless vehicles, is committed to empower vehicles with technology and promote flexible unmanned application in logistics. VisionNav Robotics provides industrial driverless vehicle products and flexible unmanned logistics solutions for manufacturing and warehousing logistics. At present, it has developed and produced a variety of unmanned forklifts and tractors, breaking through rigid demand scenarios such as 9.4m high access, 2.0m narrow channel access, driverless loading and unloading vehicles and multi-layer mobile frame stacking, which are widely used in automobile manufacturing, tire manufacturing, transportation, food, petrochemical, e-commerce logistics, third party logistics, pharmaceutical and other fields.

VisionNav, Korea MAT에서 최신 무인 산업용 자동차 및 솔루션 선보여

세계 굴지의 무인 자동차 공급업체 VisionNav Robotics가 국제물류산업대전(Korea MAT)(2021년 5월25~28일)에서 유연성과 광범위한 용도를 자랑하는 최신 무인 물류 솔루션을 선보였다. 무인 기술에 IIoT(Industrial Internet of Things) 기술을 결합한 이 신규 솔루션은 복잡한 시나리오에서 신속하게 무인 물류를 실현하고, 기업이 물류 효율성과 디지털 관리 역량을 높일 수 있도록 지원한다.

2016년에 설립된 VisionNav는 무인 산업용 자동차에 인공 지능(AI), 환경 인식, 딥러닝 및 서보 조종장치 기술을 적용하는 데 전념하는 기업이다. VisionNav는 세계 곳곳에서 65건이 넘는 프로젝트를 진행했으며, 세계500대 기업들에 서비스를 진행하고 있다 .

VisionNav 한국 세일즈 한예화 이사는  "코로나 발생 후 공장과 창고 물류 모두에서 상당한 압박을 받았다"라며 " 작업자를 대체하고자 로봇을 도입하기 시작한 기업이 점점 증가했다"고 언급했다. VisionNav와 파트너사들은 Korea MAT에서 창의적인 제품과 솔루션을 전시한다.

1. 다층 적재

VisionNav는 솔루션의 유연성과 반복 가능성에 항상 초점을 맞추고 있다. 케이지를 사용한 환경에 대해 VisionNav는 케이지의 다층 적재와 제품의 무인 다층 적재 솔루션을 내놓았다 .자동차와 식품 같은 제조 산업에서 이와 같은 솔루션을 필요로 한다. 또한VisionNav는  새로운 알고리즘과 하이브리드 센서도 이용하여 타 업체보다 물류 효율성을 300% 높일 수 있다.

2. RFID가 장착된 공유 팔레트

내장 RFID 칩과 빅 데이터 세트가 장착된  공유 는 무인 지게차의 물류 흐름을 바탕으로 상품 정보를 추적하고, 정보의 흐름을 일치시킬 수 있다. 또한, 이는 트럭 상하차 효율성을 최소 50% 높이고, 운영비를 낮추는 데 일조한다. 이와 같은 공유 팔레트는 100% 재활용 및 재활용 가능한 플라스틱으로 제작하기 때문에 탄소 배출량을 줄이는 데 기여하는 한편, 환경 보호에 유리하다.

Interact Analysis에 따르면, 2020년 이동로봇 출하량은 70,602대이며  이에 대한 총수익은 23억5천800만 달러를 기록했고, 2024년에는 140억 달러를 돌파할 전망이라고 한다. 일본이나 한국 같이  첨단 제조 산업이 번성하는 나라에서는 많은 기업이 노동력 부족하고 인건비가 높아지는  영향을 상쇄시키기 위해 물류 로봇을 도입하고 있다. 이것이 바로 Korea MAT에서 새로운 물류 기술이 부상하고, 공급망을 위한 새로운 가능성을 제시하는 이유다.

VisionNav showcased latest driverless industrial vehicles and solution at KoreaMAT

VisionNav Robotics, a globally leading supplier of driverless vehicles, showcased their latest unmanned logistics solution for flexibility and expansive applications at KoreaMAT（May 25-28, 2021）, the largest international logistics exhibition in Korea. Combining driverless technology and IIoT (Industrial Internet of Things) technology, this new solution can help companies quickly realize unmanned logistics in complex scenarios, and improve logistics efficiency and digital management capabilities.

 

(Pic: VisionNav showcased driverless forklifts at KoreaMAT)

 

“Since the outbreak of the epidemic, the logistics (both factory and warehouse logistics) has been under tremendous pressure, more and more companies have started to introduce robots to replace manual operations”, said Vivian Han, Sales Director of Korea at VisionNav. As one of the earliest companies providing driverless industrial vehicles, VisionNav and its partners exhibited creative products and solutions during the show:

 

1.   Multi-Layer Goods Stacking

VisionNav always focus on the flexibility and replicability of the solution. Based on their previous multi-layer stillage stacking application, VisionNav introduced multi-layer goods stacking application. "Stillage stacking and goods stacking have much technical things in common, and these solutions have wide range of needs in manufacturing industry such as automobile and food.”. VisionNav also use new algorithm in the new application, which can improve logistics efficiency by 300% compared to other algorithms in the market. In addition, adding hybrid sensors for motion control also provides more reliable environmental data for stacking control.

2.     Shared Pallet with RFID

Shared pallet with built-in RFID chips and big data set can track goods information and match information flow with the logistics flow of driverless industrial vehicles. It can help to improve truck loading and unloading efficiency by at least 50% and reduce operating costs. These shared pallets are made of 100% recyclable and sustainable plastics, helping to reduce carbon emissions and making benefit to the environment.

According to data from Interact Analysis, shipments of mobile robots was 70,602 units in 2020 with total revenue of 2,358 million dollars. The revenue is expected to exceed 14,000 million dollars in 2024. For countries such as Japan and South Korea who thrives in high-end manufacturing, many companies are introducing logistics robots to revert their supply chains and counter the impact of labor shortages, This is also why new logistics technologies are emerging at this year’s KoreaMAT, providing new possibilities for the supply chian in manufacturing industry. “We see three trends that are taking place in the market, which exactly are also our directions to distribute our layout” said Vivian,

1.     Strong demand in logistics scenarios, especially for difficult and complex applications, such as truck loading and unloading, high-speed sorting, and high-level storage and retrieval.

2.     Customers prefer solutions with high flexibility. Instead of introducing large automated warehouses, most of the manufacturing companies are looking for more economic and smart solutions that conform to the existing business processes;

3.     SaaS platform based on IIoT technology becomes a trend. Particularly when 5G communication is popularized gradually, Internet of Things (IIoT) can help to improve corporate decision-making and management capabilities.

VisionNav was founded in 2016 by a PhD team from The Chinese University of Hong Kong and The University of Tokyo. The company is committed to applying artificial intelligence (AI), environmental perception, deep learning and servo control technologies to driverless industrial vehicles. VisionNav now has completed its B2 round funding of totally $15 million, which is led by IDG capital, Lenovo Capital and Eastern bell Capital. So far there are more than 50 projects deployed all over the world, serving many Fortune 500 companies.