Robotics & Automation in the Warehouse

Logistics without people?

The megatrends of digitalization, automation, and autonomization will shape logistics processes in the future. Increasingly precise sensors and more powerful software will enable systems to perform the work of human specialists in more and more areas. Is this the beginning of a warehouse without people?

It's not entirely unlikely, as the development is already well advanced. For many people, robots have become indispensable in everyday life. The use of industrial robots in manufacturing has long been standard practice. Logistics, however, has lagged behind. This is primarily because robots are more or less blind and deaf. They don't lack strength, but rather the senses of humans. And to function smoothly in warehouses, future generations of robots will need to master precisely these senses.

Gripping objects of varying types and textures remains a particular challenge. Nevertheless, robots are being used more and more frequently in warehouses. According to a survey of 200 European logistics experts conducted by real estate developer Jones Lang LaSalle , approximately 50 percent stated that they already use automation technologies in their warehouses. Of these, 55 percent already employ robots.

Robots are changing logistics

And the market continues to evolve. This is due in no small part to the strong growth of the logistics sector and the resulting labor shortage. The superior performance of automated processes in terms of precision, speed, and operating time (keyword: 24-hour service) is another reason for the trend toward robotics.

There's no doubt that the fully automated warehouse with automatic delivery by drone or robot right to the customer's doorstep is still a long way off. However, the beginnings of this development are already visible. Amazon is once again leading the way, having acquired the robotics manufacturer Kiva . These devices automatically transport goods to picking stations, saving staff time and effort. Currently, 13,000 of these units are said to be in operation in Amazon's fulfillment centers .

Picking robots are taking over the job of warehouse workers

Besides Amazon's Kiva system, there are a number of other developments that are continuously expanding the range of applications for robots in intralogistics:

Fetch and Freight

Fetch Robotics has developed a picking system consisting of two robots (named Fetch and Freight) . The duo performs its tasks independently, navigating autonomously through the warehouse on its wheels. At the shelf, Fetch uses its extendable gripper arm to retrieve the desired item. Its partner, Freight, is equipped with a basket into which the goods are placed. Once the basket is full or the order is complete, Freight transports the goods to a picking station.

Toru and Kado

Magazino takes a more advanced approach with its transport robot Toru. Similar to Fetch, it navigates autonomously through the aisles and works through pick lists to bring the goods to the picking station once the order is completed.

Where a warehouse worker would normally wait to prepare the delivered items for shipment, another robot developed by Magazino can be deployed. This robot, Kado , functions as a picking station, meaning it receives the delivered goods using a scanner and camera, identifies them, and then prepares them for shipping or the next production stage.

The combined use of both devices could make it possible in the future to manage a conventional shelving warehouse entirely without human labor. But the use of these electronic assistants makes sense not only there: Automated small parts warehouses, shuttle systems, and paternoster warehouses can also benefit from the picking station. In these systems, too, the Kado can be integrated at the picking opening instead of the usual packing station – precisely where the warehouse worker currently stands.

Baxter

The Baxter, a robotic solution from Rethink Solutions, was specifically designed for safe collaboration with humans. Unlike conventional industrial robots, the Baxter belongs to the generation of collaborative robots (KOBOTs) that interact closely with people. Using its sensors and camera technology, it constantly scans its surroundings and slows down as soon as people are nearby.

Furthermore, it uses its camera eyes to identify and grasp objects. Thanks to precise force sensors and compliant arms, Baxter integrates well into a wide variety of environments. This collaborative system can be flexibly adapted to a broad range of applications: it can stack containers at the picking station or perform co-packing tasks, such as filling cartons with goods.

Exoskeletons: A middle ground between humans and machines

Besides the use of pure robots, there is an intermediate solution: exoskeletons that mechanically support and relieve humans in their work. The Fraunhofer Institute has developed such a skeleton, which is suitable for use in logistics.

While body-worn support structures already exist, they are currently relatively heavy and restrict the wearer's freedom of movement. This is precisely where the Fraunhofer Institute's approach comes in. The device integrates drive modules at the wearer's elbows and shoulders. These allow for quick and intuitive movements, enabling the user to move freely.

Furthermore, an external spine relieves strain on the wearer's back. Instead, it cushions the load-bearing forces onto the hips or the ground, thus allowing for an ergonomic working posture. Pressure sensors in the glove measure the weight and therefore determine the force applied to the device. According to the institute, the project will enter practical testing this year and could be ready for market in about four years.

CONCLUSION

Experts believe that the increasing use of robots in intralogistics will significantly boost productivity. Furthermore, it will influence the location strategies of logistics companies, as labor costs will become much less important.

It therefore seems that it is no longer a question of 'if', but merely of 'when', until robotics will become widespread in logistics.

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