While the first two "stretch" robots from Boston Dynamics, which Arvato has put into operation at a site in Louisville (Kentucky), can't yet do Pilates or yoga, they can be used to automatically and damage-free unload a wider range of different cardboard boxes from containers.
Many have struggled to find solutions capable of handling differently sized and textured cardboard boxes without damage. Stretch's unique feature is its specially developed robotic arm with seven degrees of freedom and an adaptive vacuum gripper that works in conjunction with an environmental perception system to handle the widest possible range of different cardboard boxes. Stretch has a compact base that can move in any direction and easily overcome ramps or other obstacles. A periscope-like "perception mast" uses advanced machine vision for fast and precise identification of the packaging boxes.
The mobile robots are self-contained and require neither electricity nor compressed air to operate. The image processing system identifies the front of each box in a container and then decides in real time which boxes the robot should pick and how. The individual robot arm is equipped with a gripper at the end, consisting of multiple rows of suction cups, allowing it to grasp boxes from various angles and carefully place them onto a conveyor belt.
The multi-picking function has already enabled higher throughput, especially with smaller, lighter cartons. Stretch can also multi-pick heavier cartons, which manual unloading teams cannot do, handle packages of various sizes weighing up to 23 kg, and operate continuously for up to 16 hours.
“Seasonal planning is crucial for Arvato’s operations,” says Rachael Miller, Senior Director of Operations at the Arvato site in Louisville. “There are often uncertainties in the supply chain. Because stretch wrapping has a very consistent unloading rate, we can schedule additional capacity where we need it. We can also schedule outside of business hours, when we don’t have a planned shift, and have stretch wrapping operated by just one employee in a single container.”
“Stretch creates efficiency in the warehouse by automating the task of unloading trailers and containers,” says Marc Theermann, Chief Strategy Officer at Boston Dynamics. “Planning and predictability are essential for efficient supply chain operations, and robots like Stretch can help Arvato maintain a consistent unloading rate while reducing the physical strain on employees.”
Miller. “From day one, we made it clear that Stretch would not replace our workforce, but would not only relieve our colleagues in the warehouse of physically demanding work, but also allow us to train them to perform more meaningful tasks.”
The partnership with Boston Dynamics initially involves the implementation of a total of ten stretch robots at various Arvato locations. Following the successful launch of the two models in Louisville, the next step will be to equip further locations in the USA and Europe.
