Expanding the automated warehouse offering by integrating AGVs and linear gantry solutions

In this real application example, Rollon helped an emerging AGV manufacturer to create a complete warehouse automation solution for a major retailer. Rollon’s experience, consultative approach and profound technical expertise in linear motion made expanding the company’s solution portfolio achievable. It’s about having the right partner to do it with.

Over the last few years, the logistics and intralogistics sectors have seen their activities increase exponentially in relation to consumer demand. The consequence of an ever-increasing online purchasing trend is having an enormous impact on the number of orders that need to be physically managed in a warehouse.

Intralogistics automation applications have “benefited” the most as a result. Designers must work hard to reduce turnaround times by creatively developing effective solutions from pick and place sorting operations to storage, retrieval, presentation for picking, packaging and palletising stages to get to the final shipping phase.

Automatic warehouses with high performance and low maintenance

When Rollon was approached to help develop a tote management system that could not be fulfilled by AGVs alone, it was an ideal opportunity to assist a company that had never integrated linear axis and gantry portals before.

Empty totes enter the warehouse after returning from a delivery round and are carried around by AGVs to various points. At some stage, a vertical lift to take totes from one level of the warehouse floor to the next is necessary. Additionally, a system to store totes in an isle racking arrangement and a system to buffer totes in racks while the order of totes with picked items is determined was also needed, such that they are delivered to the exit of the warehouse in an orderly fashion for the next round of deliveries to online shoppers.

All this had to be versatile enough to be installed throughout already existing but manually operated warehouses.

In summary, Rollon worked with the now full-Automation supplier to determine a set of desirable criteria to set them up with a competitive and value adding solution, that they could also take to market for future projects. Here are some of the key aspects we offered:

• Low maintenance:
  • Lifetime lubricated rollers and lubrication free rails – i.e., never stop to grease carriages.
  • Automated lubrication for rack driven gantries with easy-to-install replacement kits.
• High dynamics
  • Fast, quiet and low vibration systems are not only efficient, but a pleasure for employees to work around.
• Continued operation, even under difficult conditions.
  • No concerns about dirt, dust or liquid spills.
  • Low temperatures for operation in freezers.
• Versatile:
  • The possibility to extended existing isle gantry robot systems at a later date, if the end customer wants to automate in stages.
  • Completely remove and mount carriages to minimize downtime if repairs are needed.
• Easy installation in existing buildings where changing structures and floors is difficult or not possible.

The proposed solution

Faced with these requirements, Rollon proposed a solution capable of delivering the combined horizontal and vertical handling of totes.

The final implementation thus involved the use of the linear Speedy Rail axis for horizontal movement combined with the R-Smart actuator for vertical movement in a Y/Z gantry configuration.

Speedy Rail is an extremely versatile linear rail featuring an anodized aluminum profile and polymer-coated steel bearings that slide directly on the profile, essentially obviating the need for lubrication.

R-Smart, in turn, is an actuator with an aluminum profile, large-toothed belt, and LM blocks to guide movement. The actuator is easy to install, both for assembly operations and for gearbox and motor adaptation. The solution offers good stiffness to ensure proper performance in terms of cycle times, has symmetric drive heads to further facilitate assembly in multiple configurations, and offers immediate access to the belt for easy tensioning.

Finally, performance is ensured by first-rate internal components and additional features that enrich the solution. Joint alignment for longer (in theory unlimited) strokes, for example, relies on a joint kit that does not require complex measurements, and rack lubrication is automatic, avoiding the need for additional lubrication.

The partner that makes the difference

The solution proposed by Rollon, which now harmoniously interacts with the AGV architecture, enhanced the customer’s capability, and gave them the value-added edge to set them apart.

An opportunity for growth and expansion that only a winning relationship with your partners can create.

The power of rollon consulting and expertise

Rollon’s operating method is unique. In fact, the company combines in-depth knowledge of industrial design needs – working as a true consultant – with the supply of a wide range of linear motion products that substantially cover all requirements.

The combination of consultation with supply capacity as a manufacturer leads to customised support in every aspect – both when designing the solution and when supplying products, which can almost always be customised according to the specific need.

The case in question is an example of this. The resulting solution met the performance requirements, which could not be obtained without the right combination of products: suitable for operation at low temperatures, capable of handling dirt and impurities, no need for lubrication, and easy installation and maintenance.

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