New technology at Ostendorf Kunstsoffee GmbH means automated forklifts take the mundane, unattractive tasks outside—literally.
Ostendorf was struggling to achieve a safe and efficient autonomous operation outdoors. However, the collaboration between three proven specialists in the space made it possible. The forklift truck experts from Linde Materialhandling, the experienced automaters at Götting, and the market leader in sensor technologies, SICK, came together to develop the next innovation in automated materials handling.
Increased regulations regarding productivity and safety, along with the shortage of skilled workers, have fueled the trend towards the automation of industrial trucks in outdoor areas. As one of the pioneers in the sector, Götting KG already anticipated this over two decades ago and established an innovative business unit, the “FOX ” department. The department was created to expand product offerings with automation solutions for series-produced utility vehicles.
TheThethe demand for automated solutions grew because of the increasing trend of unskilled workers in the industries, industries explained Felix Weiß, Head of Industrial Trucks, Götting:
“We now have dramatic personnel shortage in companies. There is a lack of forklift truck drivers, especially in warehouse logistics, because their area of work is generally not very demanding and highly repetitive,” Weiß said. “Furthermore, shift work is seen as not very attractive. Automating the forklift trucks provides one solution to the problem, including in outdoor areas. It delivers a quick benefit, and can ultimately help the company to survive the intense competition.”
Automated machines mean sustainability
To remain sustainable, Ostendorf Kunststoffe GmbH relies on automated guided vehicle systems. The company has been one of the leading manufacturers of wastewater pipe systems in Germany for over 50 years and aims to further expand its market position through continuous investment in the automation of its material flow.
At its factory site in Vechta, automated forklift trucks have recently started taking care of the handling and transport of materials. To this end, a Linde E20 LI-Ion forklift truck was retrofitted with sensors from SICK to independently perform load handling and transport without user interaction. The AGV operates without a master controller and independently assigns itself transport tasks via sensor messages to the conveying equipment.
Boxed goods on standard EU pallets are first brought via roller and chain conveyors in front of the production halls. The automated forklift trucks independently collect the loaded pallets from there. They transport the material in the outdoor area to the temporary storage area along pre-defined routes and transfer the material to the conveying equipment to be put away. In the current development stage, the AGV connects three sources with one station with no human intervention. The expansion of the system by one source and two stations is currently being implemented.
Rugged sensor means no weather delays
The weather conditions have almost no influence on the forklift truck. Neither precipitation, flying pollen and leaves, or strong sunlight hamper the safety and functionality of the automated vehicle.
This weather independence is made possible by a sensor concept that takes all application parametersinto consideration. These parameters include vehicle type, goods to be transported, and the particular location of use and routes. Götting developed the concept at Ostendorf together with Linde and SICK and then implemented the optimal sensor solution. “The solutions of the leading safety supplier satisfy all current basic requirements on industrial automation with a clearly defined product liability for outdoor applications,” Weißn said.
Protect both people and materials with reliable outdoor sensor technology
“To protect people, Götting relies on the outdoorScan3 safety laser scanner and the Flexi Soft safety controller, and for collision avoidance and machine protection, the TiM laser scanner,” said Daniel Salas, Key Account Manager Mobile Platforms, SICK.
To pick up the pallet and then put it down again with positional accuracy, the automated forklift truck “takes its bearings” with marks on the conveyor system. It does this with the outdoorScan3 safety laser scanner, integrated at floor level. The load transfer area is designated a hazardous area. In the loaded state, the forklift truck always moves in reverse so the load cannot slip or be thrown off in case of emergency braking.
The outdoorScan3 safety laser scanner ensures the reliable protection of people thanks to intelligent algorithms and the safeHDDM® scanning technology. For contour navigation, it scans the environment in a radius of 275° and provides distance values to the system via Ethernet. The data is filtered at system level and used for fine positioning, such as when parking, when picking up and putting down the load, and at the vehicle charging station.
The TiM 2D LiDAR sensors on the roof of the vehicle are responsible for lateral protection. Its protective fields are parallel to the vehicle, which help avoid undesired access to the vehicle, collisions with objects projecting laterally into the travel path, and lateral collisions. These sensors provide a high level of performance for the field evaluation, measurement data output, have a scanning range of 25 meters, and a working range up to 270°. The vehicles use their controller and sensors to avoid any collisions with its surroundings.
This high level of collision protection can hardly be achieved from today's typical manned forklift truck. With the automated forklift truck, both materials and equipment are protected and their service life is extended. It also enjoys a high acceptance among the employees. The personnel feel completely safe, even when the automated forklift trucks are moving about in the same environment as manual forklift trucks, trucks, and employees.
Use accessories to improve your sensor performance
To further expand the functional safety and availability even in poor conditions, SICK offers intelligent accessories like the airWiper. The Wiper , which removes water droplets from the optics cover of the outdoorScan3 using compressed air. Intelligent software components also have a positive impact on the performance. The AGV Dynamic Weather Assist safety system features weather-independent dynamic protective field switching, which allows continuous operation even in variable weather conditions of rain or snowfall. The forklift trucks then reduce their speed and drive with more robust protective fields that prevent unplanned vehicle stops, and consequently, weather-related interruptions to the material flow.
Felix Weiß is delighted by the solution:
Our application shows that not only indoor, but now also outdoor logistics, can be automated end-to-end. The integrated safety mechanisms are reliable and ensure a smooth, risk-free automated material flow. Furthermore, the system enables us to flexibly respond to peak times and quickly adjust our capacities. In this way, we are shaping the “autonomous” future in close cooperation with SICK.
In conjunction with other industry leaders, automated forklift truck driving is on the horizon in many different industries. Get ahead of the curve and adopt AGV’s in your everyday processes. Still have questions?
