AI-generated image, due to NDA
Embedded Files
The Future of Assembly Movement: Agile, Integrated, Autonomous
Case Study
The Application: Autonomous Assembly Transfer in a Dynamic Factory
Imagine a factory floor where assemblies seamlessly move between workstations, orchestrated entirely by a digital task list and the manufacturing schedule. This was the vision: a fully automated and dynamic system for transporting assemblies, eliminating manual handling and optimising workflow.
The Problem: Bridging the Gap to Advanced Mobile Robotics
Our client, a seasoned integrator with a strong background in Automated Guided Vehicles (AGVs) and mobile machinery, encountered a challenge that stretched beyond their existing expertise. While proficient in line-following AGVs with differential drive systems, this project demanded a leap into more sophisticated robotics.
The requirements presented a unique set of hurdles:
This robot needed to navigate freely within the factory, guided by a central fleet management system, not physical lines.
Due to the significant length of the assembly being transported, full holonomic capabilities were essential for precise manoeuvring in tight spaces.
The robot was not intended to operate in isolation. It needed to seamlessly integrate with a fleet of similar robots, intelligently coordinating movements to prevent bottlenecks and ensure smooth flow.
The robot required intricate interlocks and PLC integration to facilitate seamless communication with the assembly stations.
The closed-source and proprietary nature of the existing software integrations added a layer of complexity to the development process.
The Solution: Engineering Intelligence and Precision
To overcome these challenges, a bespoke robotics solution was engineered from the ground up:
Kinematic Modelling and Motion Control: Given the unique robot design and closed-source nature of its core systems, the first crucial step involved developing a comprehensive kinematic model of the robot. This mathematical representation of the robot's movement was then used to create a sophisticated motion control system implemented in C++. Rigorous testing was conducted, initially in a virtual simulation environment and subsequently on a physical sub-assembly comprising a single drive/steer unit. This iterative approach ensured the accuracy and reliability of the core movement algorithms.
Fleet Management System Integration: To enable seamless integration with the central control system, a custom plugin for the fleet management system was developed. This plugin meticulously defined the robot's precise motion model and physical dimensions, effectively outlining its permissible range of movements while proactively preventing potential collisions with other robots or static obstacles.
Intelligent Traffic Management: To optimise the flow of assemblies and prevent congestion, a custom traffic rule set was designed and implemented. This intelligent system efficiently processed mission requests (assembly movement instructions) originating from the plant's PLC. By strategically planning robot tasks, the system ensured optimal utilisation of the robot fleet and minimised potential delays.
Extended Task Data Integration: The task data managed by the system was further enhanced to incorporate control signals for the robot's lifting mechanisms and communication protocols for interacting with the assembly stations. This comprehensive approach ensured a fully integrated and automated assembly transfer process.
The Impact and Benefits
By successfully engineering and implementing this complex robotic solution, we provided our client with significant advantages:
We enabled our client to undertake projects previously beyond their in-house skills and experience, positioning them as innovators in advanced mobile robotics
We delivered fully functional and integrated robotic software, saving our client the significant time, resources, and risk associated with attempting such a novel development themselves
We provided a bespoke solution tailored precisely to the unique demands of the application, ensuring optimal performance and addressing all the specific challenges outlined by the end user.
By partnering with us, our client could confidently deliver a cutting-edge solution to their end user, strengthening their reputation and securing their position as a capable integrator for complex automation projects.
This project highlights our expertise in tackling intricate robotic challenges and empowering our clients to achieve ambitious automation goals, ultimately enhancing their service offerings and project delivery capabilities.
Facing challenges in bridging the gap to advanced mobile robotics or seeking to empower your clients with cutting-edge automation? Let's discuss how Robogility's expertise can provide the bespoke solutions you need to unlock new possibilities and enhance your service offerings.Â
Report abuse