Robotics provider Safelog is implementing a project with eight mobile devices in the plastics processing industry, relying on each vehicle having its own computing unit. This allows them to communicate as agents within a swarm and exchange information with each other.
The plastics specialist Pöppelmann, headquartered in Lohne, employs nearly 2,500 people and operates around 700 plastics processing machines at six production sites, handling various stages of manufacturing. The North German company offers a wide range of plastic products, divided into four business units and serving numerous markets. These include the automotive, electrical, and food industries, as well as medical technology and horticulture. Through a company-wide initiative, "Pöppelmann blue," the company has become a pioneer in the circular economy, with the clear goal of conserving resources and protecting the climate.
Redesign of processes
As part of its "Pöppelmann digital" initiative, various business units are regularly reviewed to identify potential efficiency improvements. The most recent example concerns the K-Tech division, which manufactures high-quality injection-molded parts for the automotive and industrial sectors. Production in one of the factory halls takes place on 30 machines, which must be constantly supplied with empty containers. Simultaneously, the filled containers are positioned at the machines for collection.
Trolley drop-off
The process begins in the warehouse at the so-called "station," where empty load carriers are positioned on floor rollers in 12 locations by an electric pallet truck. Previously, these were transported to production by a tugger train with three trailers, manually uncoupled at their destination positions, and filled with injection-molded parts. All load carriers on a trailer were then placed at a machine. Thus, one tugger train could operate three machines sequentially. to downstream transferred
Noise reduced
“The tugger trains were very loud, a real noise nuisance in the halls,” says Michael Czwaluk, Logistics Team Leader at Pöppelmann, describing the previous situation. Furthermore, loading and unloading the trailers was a physical challenge for employees, no longer compatible with ergonomic principles. “In addition to increasing efficiency, it was important for us to find a solution that would reduce the physical strain on employees,” Czwaluk explains.
Trolley attachment
Finally, the scalability and flexibility of the tugger train system were inadequate. The transport sequence could not be adapted to the output of the production plant, resulting in waiting times at the machines during container exchanges. After approximately five years of using tugger trains, it was time to modernize the process with mobile robots, thereby increasing efficiency and consistently testing new technologies.
Compact design
Pöppelmann ultimately opted for the Safelog M4 lift, a mobile robot capable of handling a wide range of intralogistics tasks. Two technical features of the model were decisive in their choice. First, the M4 lift's low-profile design allows it to easily maneuver underneath and lift Pöppelmann's floor rollers. Second, with a turning radius of just one meter, the vehicle is extremely maneuverable and can easily navigate Pöppelmann's sometimes narrow aisles. "The compact design of our vehicles is one of our strengths," adds Moritz Schmidt, Head of Sales at Safelog. "This is why the mobile robots also perform well in confined spaces." The M4 lift is designed for a maximum payload of 1000 kg, which is more than sufficient for Pöppelmann's needs .
Traffic situation
Pöppelmann now has eight mobile robots in operation. Vehicle number nine serves as a backup and is only activated during peak production periods. In the warehouse, they pick up floor trolleys containing empty containers, transport them to the production machines, and place them there . The robots then pick up the full containers provided at the machines and transport them to the station in the warehouse area, completing the supply cycle. This largely eliminates empty trips by the robots. The robot fleet was installed while operations continued. Not all models were implemented simultaneously, but rather one after the other was put into operation. "We approached it gradually," says Dierken. " Our commissioning software allowed us to bring individual robots online, which led to success in a short time."
Orientation by contour points
To enable the vehicles to navigate their circuit, the halls were digitally mapped beforehand, and the data was transferred to the robots. Using the map, the devices now orient themselves by specific, fixed landmarks such as columns, injection molding machines, or hall doors. The mobile robots move along fixed, virtual routes that are defined in the digital map.
“It works so well that we were able to do without an additional magnetic track,” Dierken says happily. Pöppelmann has mixed traffic. The mobile robots therefore have to interact with other road users such as forklifts or workers. To prevent accidents, the devices are equipped with safety sensors. If an obstacle is located within the safety zones, the robots slow down or stop until the obstacle is removed.
The mobile robots don't need a control center. The system works reliably because if one robot fails, the remaining units take over. "If, on the other hand, a central control center fails, the entire fleet comes to a standstill," says Moritz Schmid. "With agent-based control, in the worst-case scenario, each unit can even continue operating independently," he assures.
www.safelog.de
