Autonomous Mobile Robots (AMRs) can locate and navigate themselves in an environment—this is how they accomplish their tasks of assembly and transportation. But how do they know where they are and where they need to be? Behind these simple questions lies the science of localisation, mapping, and navigation. This blog post explains how our AMRs, the arculees, locate, map, and navigate to ensure accurate, efficient, and autonomous movement.

Autonomous Mobile Robots (AMRs), like the arculees, must navigate different environments, such as warehouses or other facilities, to move from one place to another and perform a task. The first step to navigation is mapping, which simply refers to the process of creating a map. Before arculees can drive autonomously, we need a map because otherwise, we don't have a point of reference; we don’t know where the robot is and where it needs to go.

How do arculees Generate a Map?

Mobile robots rely on data from their surroundings to create accurate maps for navigation. They need two types of information: their own location and the location of other objects around them. The arculees collect this important sensor data through two LiDAR (Light Detection and Ranging) scanners, an IMU (inertial measurement unit), and the wheel odometry.

LiDAR Scanners: They use laser beams to measure distances to objects, generating a point cloud that is used to create a map using the robot’s software.

Inertial Measurement Unit (IMU): The IMU is an electronic device that provides data on a robot’s acceleration and rotation.

Wheel Odometry: It is the process of using data from wheel encoders to estimate the robot's position and orientation over time by calculating how far the wheels have travelled, typically relative to the robot's starting point.

Together, these tools help the arculees create a map representative of their real environment and determine their position within it.

SLAM - Simultaneous Localisation and Mapping

The method of collecting data from scanners, IMU, and wheel odometry to generate a map is called SLAM. It stands for simultaneous localisation and mapping. To create an accurate map, you also need to know where the robot is on that map, which is what localisation stands for in the acronym. With the scanners and sensors in place, you drive the robot around and collect the scanner data and the data on where the robot is. Finally, you combine that to create a map.

Once the map is there, the robot software loads the map as a reference frame and is then able to drive within it. Since the map itself has a coordinate system, the software can tell the robot where it should move and where it is, creating a route and driving from A to B.

Tools and Techniques: Mapping, Localisation, and Navigation

Localisation, mapping, and navigation are the processes that go hand in hand to ensure autonomous driving of mobile robots like the arculees. However, there are certain tools and techniques to make the processes work:

At arculus, our tools, algorithms and sensors include the SLAM toolbox, Google’s Cartographer, IMU, wheel odometry, and two laser scanners. The SLAM toolbox is an open-source 2D SLAM tool specifically developed for Robot Operating System 2 (ROS2). Both Cartographer and SLAM tools are used for real-time localising and mapping across multiple sensor configurations and platforms.

Meanwhile, there are two ways to record a map:

Offline: We create a recording by driving around the environment whose map we need and collect data. This data includes scanner information, IMU (inertial measurement unit) readings, and wheel odometry. Afterwards, we process the recording using a Cartographer to generate an offline map.

Online: We primarily use Cartographer for online recording. It simply processes live data from the robot in real time to create the map.

Once the arculees have a laser map, they can drive automatically. However, to complete tasks, operate safely, and avoid deadlocks, an efficient traffic management system overlooks the robots, giving them specific driving orders. This system lives in our fleet manager. The best path is calculated by considering various aspects such as battery charge, distance, and possible driveways where the robots can go. Therefore, our Fleet Management Software sends step-by-step instructions to the AMR, guiding it for the next actions at a time. As the robot moves, the fleet manager continuously updates the route, ensuring safe, smooth, and accurate navigation.

Current Challenges and Hopes

Like any other technological advancement, AMR mapping and navigation comes with challenges, but there are always ways to find better, more viable solutions. While our current mapping techniques work perfectly within small to medium areas, a possible caveat can be creating maps of large and dynamic environments. However, our team of developers at arculus addresses this by recording the data and later processing it offline on more powerful computers, where computational constraints are no longer a concern.

Although the present mapping processes are effective, arculus aims to improve and innovate continuously. That is why our ultimate goal is to keep updating and refining the AMR mapping methods.

Hopes for the Future

Future advancements in mapping and navigation promise faster algorithms and higher map accuracy. Improvements in accuracy can address persistent issues. For example, enhanced precision would enable robots to navigate more efficiently, reducing errors and the need for manual corrections.

These advancements hold great potential for the role of autonomous mobile robots. With greater accuracy, robots could move faster and operate even more reliably. As a result, accuracy can create a more stable and efficient solution for dynamic environments.

The Way Forward

Mapping and navigation in autonomously driven vehicles is an emerging but crucial part of robotics. As such, it has ample room for growth and advancement. While there is no silver bullet to improve everything all at once, the tools developers use for mapping and navigation are composed of smaller components and algorithms, so a slight improvement in one of the parts can positively affect the entire process. On the other hand, staying connected to recent and relevant research, reading publications and keeping oneself up-to-date on what’s happening in the field is essential for future breakthroughs. There is much room for improvement, and tools need updating, especially with artificial intelligence entering the equation.

At arculus, innovation and efficiency are the most critical factors when devising solutions. This commitment is adhered to at every stage of our Autonomous Mobile Robots (AMRs) production cycle—from prototyping and defining the different processes, to building, scaling, and testing them. In this blog post, Thorsten Mersdorf our Production Manager explains how his team produces the arculee M, our latest AMR model.

Recently, arculus introduced our latest Autonomous Mobile Robot (AMR), arculee M, to the world of intralogistics. Based on extensive market research and valuable customer feedback, the new model stands out for its enhanced load capacity, wide use case capability, good manoeuvrability in narrow aisles, and ease of maintenance. Our systematic yet innovative production processes have been pivotal in successfully delivering our state-of-the-art AMR.

AMR Production at arculus

AMR production means procuring and assembling the required components to build a functional and safe robot, ready for delivery and deployment. This crucial stage in AMR manufacturing plays a vital role in ensuring an efficient and streamlined product.

Exploring the arculee M production journey can thus offer valuable insights into making robot assembly more efficient. Thorsten Mersdorf, our Production Manager, emphasises that the AMR production processes fall into the following four categories:

1. Knowing the Product: The first stage involves being 100% clear about the AMR and understanding the required specifications through researching the market, studying previous versions of the robot, and using any insights gained for prototyping.
2. Defining the Processes: The next step is organising the data and ensuring that all the instructions at every step are clear for effective robot assembly.
3. Securing the Resources: Defining and integrating adequate tools for various purposes and building a motivated team to carry out the task.
4. Assembling and Adapting the Product: Finally, the team assembles, calibrates, and tests the robot. Moreover, flexibility, improving processes, and making changes according to market and customer needs and feedback are also essential for efficient AMR operation.

Cross-team collaboration

To support these practices, the Production department works closely with the Development teams at arculus to improve our AMRs. This collaboration is another secret ingredient behind our fast and efficient introduction of the arculee M. According to Thorsten, “Efficient production starts with the development of the products.” For example, developing separate modules for different robot components allows easy assembly and maintenance of the arculee M, by offering more flexibility and scaling options. That is just one way a decision at the development stage can affect and improve the building stage.

In addition to learning about the target product and coordinating with other departments, a lot more goes into the production cycle of the arculees. Let’s find out how to build a robot with mastery.

How to Build an AMR

The AMR production involves several key stages:

1. Pre Assemble

The actual process begins in Dresden, home to the arculus warehouse. Here, the team carefully thinks through the material selection beforehand. For example, we rely on corrosion-protected steel for the arculee M's structural components, ensuring durability and strength.

Leveraging an innovative modular approach, the arculee M comprises separate modules for different components, with dedicated teams putting each one together. This strategy allows for the pre-assembly of modules independently from the main construction, providing remarkable flexibility. It facilitates scaling and allows for outsourcing before the final assembly.

Thorsten further explains, “First of all there are the key modules. For example, the Electronics Module focuses mainly on the Robot Control Unit (RCU), also known as the robot's heart. Others include the Active and Passive Lift Module, the Drive Module, and the Chassis. Lastly we have the Auxillary Modules that cover all functional parts, such as cameras, key switches, access points to the robot, and all the UI features and environmental detection sensors.”

2. Assemble it All

The main assembly follows the fishbone principle, using cause-and-effect diagrams (resembling a fishbone structure) to create an optimal concept. Once that’s in place, the team installs each pre-assembled module into the robot. Of course, it is not simple, and the team considers several factors for aligning and securing the mechanical parts of the AMR. These include ensuring the tolerance of each part, optimising the fitting process, getting the specifications right, and maintaining strict quality control throughout the supply chain.

3. Integrate the Robot

Configuring and calibrating different components and software is also crucial for the robot's proper functionality. At this stage, the team integrates the motors and sensors into the robot via the RCU and the S7 Safety process. Effective implementation of safety features in the AMR is critical for on-site equipment and personnel protection. Other tasks covered during the integration stage include:

• Software flashing: Depending on the needs, it may include updating, resetting or rebooting the robot software for smooth operation.
• Scanner, camera, and sensor adjustments: Calibrating the cameras, scanners, and sensors is crucial to ensure that AMRs collect accurate data about their surroundings for efficient object detection and navigation.
• Robot lift system and drive configuration: Fine-tuning these systems ensures the AMRs can move and position themselves seamlessly at the customer facility.

4. Test

Testing involves checking the system, application, and performance to ensure safety and functionality. The team uses the four-eyes principle, meaning at least two people evaluate each process to guarantee accuracy. For this, we have quality checks throughout the production process. We also conduct other evaluations, such as the system test on the bench and the robot’s endurance test. The idea is to confirm that the AMR is functional according to the quality requirements and follows the safety standards.

The entire process of assembling, integrating, and testing a robot takes around 10 hours. However, the estimate doesn’t include the time spent defining the concepts and processes, or arranging the modules.

5. Have a Cool Team

A group of people who are passionate about what they do is one measure of the success of any project. The production journey of an AMR, like that of arculee M is no different. As Thorsten explains:

“Teamwork is also extremely important in production. If we don’t align the team towards a goal, we won’t be able to harness the skills of each individual in the best possible way. As a result, we’ll fail to awaken the required ‘winning spirit.’ But if we create the right environment, teamwork can develop, and the members will trust each other and ultimately enjoy taking on challenges and solving problems.”

Thorsten takes pride in the squad - a group of highly talented, driven, and creative individuals:

Jonas Jaeger is the Team Lead for Assembly and Integration and manages teams, resources, and the production area in general.

Federica Granato and Anika Lorenz, the Production Engineers, are responsible for quality assurance for the arculees and the warehouse management.

Josef Bauer and Marcel Trouillaud are the Mechatronic Experts. They cover integration and end-of-line processes.

Tamas Szipli is the Production Expert. He handles key resource assembly, tooling, and planning.

Diego Hidalgo, Integration Expert in Mobile Robotics, tackles tasks related to software and the robot UI.

Konstantin Bikard and Stefan Klein, the Production Technicians, take care of the assembly and equipment setup and adjustments for safe, high-quality robots.

Fazli Senel is the Robotics Service Engineer. He tests and maintains the AMRs for efficient robot operation.

“If you take a closer look at production and its environment,” continues Thorsten, “teamwork is one of the main factors contributing to smooth processes and good product quality.”

6. Have the Right Tools to Hand

The other crucial resource for efficiently building agile robots is the tools. When it comes to specific equipment, Thorsten mentions various items for different stages of AMR production:

• For organisation: To effectively structure and manage tasks and processes, we use different software such as operations1, Assemblio, and Jira.
• For assembling: Depending on the task, the team may use various tools. Usually, these include assembly tables, cranes, and torque screwdrivers.
• For calibration and testing: We have equipment and calibration benches for post-assembly configuration and software packages to optimise the performance of the AMRs. We also use the self-developed Robot UI for several End-of-Line (EoL) processes to ensure the proper functionality of the AMRs.

7. Have an Awesome AMR - the arculee M

Once the arculee M is built and functional, it is ready to transport materials in warehouses, supporting the automation of the intralogistics industry. The most impressive specs of the arculee M include:

• Flexibility with transporting of pallets
• More room for higher load capacity, i.e. 1,300 kg
• Effective obstacle avoidance system
• VDA 5050 compatibility

If you want to adopt the arculee M as a solution in your facility, please visit Jungheinrich for more information.

In short, arculus with its continuous commitment to innovation, assembles and integrates the arculee M as an efficient Autonomous Mobile Robot for intralogistics. To sustain this success, it's essential to remain agile and responsive to the ever-changing technological advancements and dynamic demands of the intralogistics industry. By continually adapting, evolving, and optimising our processes, Thorsten’s team turns these challenges into opportunities, advancing our production standards and contributing to the ongoing advancements in the field.

In this blog post, meet Linus Ferlinz, Product Owner, and Fabian Na, Senior Mechanical Design Engineer at arculus, as they discuss the mechanics of our latest Autonomous Mobile Robot (AMR), arculee M, focusing on its versatility with different backpacks and stations.

The Functionalities: Backpacks, Stations, and the arculee M Mechanics

What are the different types of backpacks and stations currently available, and how do their functionalities differ?

Linus: The reason for having backpacks is to facilitate a variety of use cases. For example, our customers have pallets. Depending on the use case and the factory layout, you can transport pallets lengthwise as well as crosswise. Now, backpacks allow us to adapt a robot for different tasks without needing another variant of the robot. We can do that just by adding another backpack on top.

How does the arculee M's mechanical design ensure compatibility with various backpacks?

Fabian: The mechanical design is, in a way, a universal interface between the base product and the backpacks. So, we have the same mounting positions and electronic interface for all the backpacks. As a result, the base product of the arculee M never needs to change, and all the backpacks are compatible.

How does mechanical design ensure durability and ease of maintenance, especially considering the environments the robot will operate?

Fabian: We understand that our Autonomous Mobile Robots (AMRs) are used in highly industrial environments where durability and safety are crucial due to the possibility of workplace hazards. Additionally, we prioritise serviceability and maintenance by ensuring service technicians can access all components without needing extra tools, facilitating efficient field maintenance.

Integration between the Backpacks, Stations, and the arculee M

What are some key considerations in ensuring seamless integration between the robot, its backpack and the stations?

Linus: One of the strengths of arculus is our close-knit working environment. So we have the production in the same building as the software and hardware development. As a result, we constantly interact in the office, even on breaks, such as in the kitchen and at the coffee machine. This facilitates collaboration. Moreover, we discuss topics and progress during our biweekly sprint reviews, ensuring feedback for different departments. Finally, at the same time, on the team level, we have daily alignments on topics we're working on to ensure that we all work in the same direction and have the same focus.

Fabian: So it's not like segregated departments work in their own directions. Instead, we're all working together on the product as the final goal. And I think that's something special that arculus does.

The Creation Process

What does the design and development process for a new product typically involve?

Fabian: The process starts with the conceptualisation phase. We base it on the product requirements and try to meet the functionalities with any concept possible. Once we have a couple of concepts, we typically do some sort of decision matrix to determine our best way forward, and then we go into a detailed design process. Of course, we're keeping the product's functional requirements and technical specifications in mind during this whole time. That's how we make sure that the product works.

How do you ensure that new products meet both technical specifications and user needs during the development process?

Linus: A very important point here is that we are all involved in testing our products. So, we have a testing area in the building, and everybody, including the developers working on the mechanical design, can go there and test their product - This is the very first step. For example, when we have a proof of concept or a prototype, we can test it and see how it feels and works. Then, in the next stage, we have pilot phases in our internal factories at Jungheinrich, where we can get customer feedback before we roll out to external customers.

Fabian: Additionally, the technical specifications we define for our new products typically come from the use case and user needs. So we really try to focus on, for example, what performance our customers need to stay competitive. Such requirements are then translated into the technical specifications for the product.

Linus: Another critical point is our use of short, iterative cycles during development. We can quickly adjust our approach if something isn't working as planned. This flexibility allows us to change direction whenever necessary, ensuring we stay on the right track.

Were there any specific components or systems that required extensive testing or redesign?

Linus: We recently had this one situation when we changed the navigation method, a significant change for many of our products. We collaborated very closely with our software team to align on the visual detection of, for example, our handover stations. The solution included iterating our station design, significantly impacting the overall products.

Was there a point where you had to balance mechanical complexity with functionality or cost? How did you navigate this?

Fabian: I would say that mechanical complexity results from balancing functionality and cost. So, as a mechanical design engineer or any type of engineer, when you're designing something, there are three main factors:

1. Cost
2. Time
3. Quality

Depending on which of those three factors is the priority for the project will determine how complex the system will have to be. So, the day-to-day work that we do includes trying to balance and manage these three factors of how we can design something cheap but also, let's say, complex enough to achieve the functionality that we require.

Linus: You might also need to consider the product's stage. For example, at a very early stage, you just want proof of concept. Maybe costs are not the highest priority at this stage. Once you have checked that it's working how you want it to, you can move on to the next stage and optimise it for costs.

Can you discuss the process of creating custom-designed backpacks for specific customer's needs?

Linus: So we get those inquiries from the customers. Our first step is to ensure we have all the necessary data. This includes understanding the layout of their sites to verify all accessible driveways. Once we have this data, we can either redesign the load carriers or obtain CAD (Computer Aided Design) models from the customer. We then check if our existing portfolio can accommodate these load carriers. It's always good if the company doesn’t have too many different components because keeping the parts inventory manageable is crucial. However, we will create a customised design for the specific load carrier if our existing options are insufficient.

How does each of you view the most impactful functional improvements in the arculee M compared to the arculee S?

Linus: I think the most important feature of the arculee M is its increased load capacity of 1.3 tons. Despite this higher capacity, it maintains the footprint of a standard pallet, making it ideal for carrying industrial pallets. Additionally, the new AMR offers greater compatibility with load carriers, allowing it to transport pallets both lengthwise and crosswise, a capability not available in the arculee S. This focus on pallet transportation makes the arculee M truly versatile.

Fabian: We have made significant strides in the design of the arculee M, focusing on assembly, serviceability, and design simplification. These improvements ensure that the product is durable and long-lasting. Additionally, this new AMR is easier to maintain. Overall, we've enhanced general performance to guarantee that arculee M will remain reliable in the field for an extended period.

The Functionalities of the arculee M

Can you discuss a specific functionality that you personally worked on or found challenging?

Fabian: There are a lot of complex assemblies inside the product. One of the challenges is to find a solution that can withstand the forces and the dynamic conditions that the product will be experiencing in the field. So it's, for example, the lifting system. It's not simply lifting something up and down; we must reinforce the system by breaking centrifugal forces when driving in curves. We have made some very big strides in the design of how we provide this robustness to our product.

How did your approaches differ during development?

Fabian: During the development process, we worked closely together. We focused on meeting the requirements, like ensuring the AMR can lift and travel fast enough. But we weren't, or at least, I wasn't so far in depth with how we’re transporting load carriers and the whole backpack floor station aspect of it.

This is all about backpacks, stations, and the arculee M mechanics. Watch the entire interview below!

The electronics of Autonomous Mobile Robots (AMRs) play a key role in determining their functionality and efficiency. The same goes for arculees, our AMRs. Join Tobias Schwering, Andres Magallanes, and Jolly Jacob from the arculus electronics team as they explain how the arculee M, our latest product, builds on the electronics strengths of its predecessor, the arculee S, but also offers several advanced features.

The Evolution of Electronics: From arculee S to arculee M

Can you describe the evolution of the electronics aspects from the arculee S to the arculee M? What were the key improvements or changes made?

Tobias: One of the main goals for the arculee M was to ensure fast development. To achieve this, we reused as many components from the arculee S as possible, thereby accelerating the process. We identified key parts that could be reused, starting with the RCU (Robot Control Unit).

The RCU, initially designed for the arculee S, was adapted for the arculee M with some additional functionalities to support new use cases. For instance, we incorporated a safety concept for ramps. We have not designed the S to navigate ramps, but the arculee M can go up to 10-degrees on the ramps. So, this was a big thing. Besides adding these few interfaces, we made general improvements to the RCU. However, for Andres, the harness presented different challenges.

Andres: The harness plays an important role in the mechanical and electrical design of a robot. There was a major change here from the arculee S to the M. In the S, we used a single long harness, which, if you put it on the table and extend it, will probably be three meters long. In contrast, the arculee M features a more modular approach. The modular approach means splitting the harness into different modules. Therefore, we easily replace, handle, and manufacture them, simplifying the assembly process during production.

However, the harness differs not only in modularity but also because of the new components it supports. We have introduced different devices, such as upgraded scanners and new data communication interfaces, marking a substantial evolution from the arculee S.

Tobias: Perhaps we should clarify that when we mention "scanner," we refer to the safety laser scanner. This type of scanner ensures our robot can operate safely around humans, making it functionally safe. Additionally, we use the safety laser scanner for navigation purposes.

Jolly: Another aspect to consider is the design. We had already tested many RCU modules with the arculee S and found them efficient and high-performing. Therefore, we retained these modules in the arculee M without compromising efficiency or performance. We took the proven modules from the arculee S, integrated them into the new RCU, and made necessary modifications to suit the new robot.

The Technical Aspects of the arculee M Electronics

What are some of the most significant technical innovations in the electronics of the arculee M?

Jolly: The camera used in the arculee M would be an innovative technology, and the brake control board, with its sensing method, would be a technological advancement, too.

Tobias: We updated our safety scanner system to provide more precise laser data. This enhancement improves the entire software stack, leading to better localisation, system navigation, and more robust performance.

Jolly: Another important change, though not a major technical one, is the modification of the LED light. Previously, it was pretty large and used a lot of space. We have now significantly reduced its size to less than half, making it more efficient and directing the light precisely where needed.

Andres: In this new project, we took a different approach to designing the harness using computer-aided design (CAD). Previously, we would create a prototype harness for the robot, document the length, estimate wire coupling lengths, and then compile a bill of materials based on what we used or had available.

While we had electrical documentation specifying the connection procesdures, we lacked detailed documentation on how to build the harness. Now, with the CAD approach, we have integrated the harness design into the 3D design of the entire Autonomous Guided Vehicle (AGV). This method is easier for manufacturers to maintain and handle, allowing for the direct creation of production drawings.

Jolly: The new approach allows us to easily remove parts for testing or modification with the arculee M. We had not implemented this method in the arculee S. It’s a valuable addition that we can use in all scenarios, including testing during production and maintenance.

Tobias: It was mainly designed for production so that we could pre-assemble modules. That was the main idea, I think. But then we realised that it also has several other advantages. So now you can just exchange parts. For example, if something breaks in the field, we can just ship one part there and exchange it.

Andres: Now, we are more interested in making it easier to produce, assemble, and maintain and repair on the field. So, if one reset button is not working, we can just remove the panel, replace it with a new one, and then investigate what the problem is with this button.

Tobias: Well, a robot is just such a complex thing. So we call it always the integration phase - the first time a robot is built, and then we put everything together. And there were tests upfront. But your tests are never complete until you have a complete robot. The completion of this, with every single robot that I saw, usually would take a long time. However, with our modular approach with the arculee M, more people could work on it in parallel, which sped up this process.

After all, that's one of the key points where speed and efficiency in development are required.

How have power management and efficiency been improved in the new electronics setup?

Tobias: The biggest addition was the deep sleep feature, which allows the robot to reduce its power consumption to extremely low on a remote command. Also, the robot can restart itself — it all comes from the fleet manager!

Except for that, I think the power consumption and efficiency were already pretty great in arculee S, and arculee M is now also relatively efficient. We have our completely self-designed inverter system, which is very power efficient.

Jolly: One improvement is to speed up the lift timing. So we just increase the speed of the lift, and in that way, we save some operation timing. Also, we just changed some circuitry with proper DC converters, ensuring more efficiency. Initially, we had designed for more power, but we don't require it with arculee M. So, we redesigned those sections to save some power.

Tobias: The arculee M weighs nearly twice as much as the arculee S. It can lift more, and move around more with less power consumption.

The Challenges of the arculee M Electronics

What were some of the biggest challenges faced in developing the new robot, and how did you overcome them?

Tobias: One of the biggest challenges was the time frame. We wanted to develop arculee M very quickly. However, we had to make changes to the RCU, including adding new interfaces. For example, we introduced a new front camera and 3D camera system, which required an additional Ethernet interface on the RCU.

We had to push out a new revision of the main board fast. Since it’s a large PCB (Printed Circuit Board), we had to order, assemble, test everything on schedule before starting real integration. So, fitting this into the development cycle while ensuring enough time for proper testing was a significant challenge.

Andres: Also, this braking board is a very interesting system because, according to the current, you can detect the opening and closing of the brake. The industry already uses this principle, but not so widely. And yeah, implementing it here was a new experience overall.

Jolly: We quickly assembled our new PCB for the brakes and other components, tested it, and debugged everything to ensure it worked as expected. The tight timeframe was, thus, one of the challenges we faced, requiring us to keep working at full speed.

Tobias: But overall, we did three revisions, and had to add only one connection. Over these two revisions, we added two resistors. Besides, we have now built a technology base that we can use in the future, for example, for electronics module development.

Integration of Mechanics with arculee M Electronics

How do the robot's mechanics and electronics integrate to enhance performance and reliability in the new model?

Andres: Well, I think the harness makes a great example. Moving from a big, fully integrated harness to a modular approach required us to work with the mechanics department. Of course, the design initially comes from the electronics, which places all the components you need there, estimating wires, cross-sections, cables, and all the signals that need to go. But as I mentioned before, it's now fully integrated into our robot's CAD system, which is where the mechanics enter the picture.

Tobias: The modular approach made achieving electromagnetic compatibility (EMC) more challenging. We must adhere to some limits regarding how much a robot can radiate. Of course, we've managed to do it with the arculee S - we have passed the official certification in an accredited lab. But with arculee M, everything was larger, and there were more connectors where the wires were pulled apart for easy access and more interconnections in the single parts. So, it's not one single structure that works as a shield anymore. This meant collaborating with the mechanics department to develop a system that fulfilled the modular approach's requirements without ruining the robot's EMC capabilities.

Jolly: There were some other areas where electromechanical integration was necessary. For example, if we had to place a PCB in a different part of the robot for lighting, we needed to fix a position for that. The mechanics team would help place it at a proper angle and in a certain way. Similarly, mounting the battery was also where the electromechanical integration was crucial.

The arculee M Electronics: Lesson Learned

Let's talk about the lessons learned. What lessons learned from the development and the deployment of the arculee S were applied to the new model's electronics?

Andres: One thing we have learned while developing arculee S was that if you want to be fast with the design, you need to parallelise the work with other teams. You cannot block the next team's work; it will never work, and we implemented parallel working for the arculee M.

Tobias: But it goes both ways because we also learnt what strategies and components used in the S were really good ideas. For example, the drive system and our self-developed inverters turned out to be more or less one-to-one usable in the arculee M. So, of course, there were lessons about things that were not so well with the S, but also about what worked and can be used as it is in the next robot.

Andres: We just changed some parameters because we used different motors with different physical characteristics, but that was all!

Tobias: Yeah, but only for lifting. The drive motors we used for the arculee M only have a stronger brake. The rest is the same. So, that was only for the ramp. As we discussed, the arculee M is heavier, can carry more, and can stay on ramps. So, it has to be stable and shouldn't start moving them. This is why we had to beef up these electromechanical brakes a bit. However, that was not in the scope of the arculee S.

Moreover, we added the brake controller board, a supervision feature. The idea was to ensure the brakes are actually were stronger and working before we introduced them to the driving into ramps! Otherwise, that might be dangerous. Since functional safety is a major topic in many design decisions, including electronics and AMRs work in close collaboration with humans, we must ensure that nobody gets hurt working with a robot.

Jolly: Also, we tested this with an actual load, not in a simulation. So we put the real load on and applied the brake while moving. Then, we performed all the tests immediately to ensure everything was working perfectly.

Tobias: Moreover, our basement room at the old office wasn't large enough for the brake test. You know, to bring the robot with a weight of 1.75 tons - actually, we even tested with overload, so 2.05 tons, to full speed and then brake. But we managed to find suitable test halls then, thanks to Jungheinrich, our mother company.

However, with the new office, one of our biggest concerns was how much the floor could take. Thankfully, we have access to a great testing area now!

This is all about the arculee M electronics. Watch the entire interview below!

Commissioning a technology is an important part of its efficient deployment. This also holds true for an innovative product like an Autonomous Mobile Robot (AMR). In this blog post, Thorsten Mersdorf, our Production Manager explains how arculus commissions its AMRs (arculees) to ensure their seamless operation, especially in intralogistics.

Intralogistics is continuously growing, with more automated solutions and advanced technologies surfacing. One category of product at the forefront of this revolution is the Autonomous Mobile Robot (AMR). Deploying an AMR involves multiple stages, with commissioning being an essential step of the process.

What Makes Commissioning Special?

Since the final testing and configuration come after the main robotic assembly, commissioning is chronologically, the last part of the production process. However, from AMRs development to sales, Thorsten Mersdorf, Production Manager at arculus, believes it to be the central step in the AMR’s production cycle.

According to Thorsten, “ Without first commissioning, it is impossible to test an AMR for performance, functionality, and durability. In short, it is the measure of quality delivery.” He further emphasises that this is the stage when the test engineer knows that all the features of the AMR, such as navigation, lift, drive, and safety, are working correctly. This also includes setting up the environment for the customer’s operation site before handing over the robot.

Commissioning guarantees the Customer Success team receives an AMR that is ready to use on-site. The more diligent the processes, the easier and faster it is to integrate the robots at the client’s site. The production team at arculus ascertains this diligence by identifying specific standards and applying them to the testing procedures.

AMR Commissioning in Intralogistics

Commissioning of AMRs includes different key steps. Thorsten summarises them as follows:

• Calibrating the Scanners: This involves fine-tuning the scanning systems within the Automated Mobile Robots (AMRs) to ensure accurate detection and interpretation of surroundings.
• Calibrating the Drives and Lift: Here, the team calibrates the AMRs' drive and lift mechanisms to optimise performance. This guarantees smooth movement and precise positioning of the robots at the facility where they will operate.
• Performing Dry Runs: After calibration, the production team runs tests to make sure everything functions correctly. This allows them to observe how the AMRs operate in a controlled environment before deployment, helping to identify any issues and further fine-tune the system.
• Flashing Safety and Software Release: This phase ensures all safety protocols are properly configured and activated within the AMRs. Safety features are critical to preventing accidents and securing the protection of personnel and equipment on-site.
• Brake Tests: The brake tests evaluate the effectiveness of the AMRs' braking systems under different conditions. Testing both with and without a load, ascertains that the robots can safely come to a stop, even when carrying cargo.
• Performance Testing Based on Customer Use Case: Finally, the performance of the AMRs is tested based on the specific requirements of its future operation scenario. This includes evaluating factors such as speed, accuracy, and efficiency in completing tasks relevant to the customer's workflow.

The Standards of AMR Commissioning

According to Thorsten:

"Creating standard operating procedures (SOPs) is the start of the production process. They offer a consistent strategy for test engineers to follow in the future. When test engineers prepare an AMR for user operation, they use the pre-defined strategy. This approach saves time during commissioning and delivery, since the team doesn't have to develop procedures from scratch."

Finally, staying in touch with the latest innovations is necessary. As Thorsten explains: 

“The half-life of safety and software releases is very short. Therefore, maintaining a close interface with development is important to react quickly and appropriately to the latest advancements. This includes evolving the test routines and procedures accordingly, as well as improving the error correction mechanisms for our test engineers.”

Commissioning AMRs for Warehouses

Commissioning a robot also depends on the specific application scenario. According to Thorsten, even commissioning AMRs for warehouses can be dynamic in some ways. For example, the commissioning may vary depending on whether the use case will be table pallet transport or backpack transport. At arculus, we plan the corresponding commissioning processes based on these practical implications.

Commissioning Challenges and How to Solve Them

Commissioning autonomous mobile robots (AMRs) for intralogistics poses several challenges that need innovative solutions. Thorsten talks about some common hurdles:

• Shorter Delivery Times: In some cases, the finished product needs to be delivered quickly. Due to this time shortage, managing commissioning processes in such scenarios can sometimes require extra effort.
• Use Case Diversity: The diversity of use cases poses another significant challenge. Tailoring configuration, testing, and other routines to specific customer operations is necessary. Therefore, when diverse applications are required, the team adjusts these commissioning processes accordingly.
• Increasing Safety Requirements: From ensuring compliance with industry protocols to catering to the safety requirements for specific use cases, AMR commissioning can get tricky. However, arculus has safety standards in place to effectively address these needs.

Innovative Solutions in Action

Since challenges are part of the job, Thortsen talks about how the production team at arculus addresses them. “For example”, he explains, “working with the scanners of the arculee S initially required more time and energy. We implemented an improved installation and adjustment process for them to address this, thus accelerating and stabilising the commissioning significantly.”

Future Trends and Innovations

The production processes of autonomous mobile robots (AMRs) for intralogistics are evolving rapidly, driven by technological advancements and shifting industry demands. Thorsten explores these future trends and innovations that are shaping this domain:

• More Automation: There's a clear trend towards automating commissioning. The goal is to reduce setup time while ensuring higher quality assurance. Efficient data management is thus crucial to derive insights for future software and hardware improvements, ensuring better commissioning efficiency and reliability.
• Integration from Production to Customer Sites: As AMRs transition from production facilities to customer sites, there are always a few challenges to navigate. Moreover, growing customer and industrial demands sometimes result in delays. While arculus has established stable processes to handle these anticipated issues, ongoing innovation and optimisation are consistently pursued to further enhance efficiency.
• Fleet Management and Host System Integration: Effective fleet management and integration with host systems are crucial for optimising AMR operations. Expending energy to improve the AMR alone is never enough. Even if the most advanced technologies are used to optimise the robots, implementing robust and powerful interfaces to the supervisory system is also necessary for smoother commissioning.
• AI-driven Commissioning: Finally, artificial intelligence (AI) has significant potential in AMR commissioning. AI algorithms allow faster calculation and prediction, thus efficiently designing tests and automating production processes. However, one must be careful with its long-term usage to ensure consistency and quality. In this regard, continuous monitoring, checking and optimising AI technology will be the key to successfully implementing and automating AMR’s production processes.

Thorsten is positive that arculus is prepared for this evolution of commissioning. As he puts it:

“One way arculus is addressing the technology revolution is through the continuous development of the product. From the central hardware components to the software features of the robots, there is a constant process of innovation. This is valid for our DevOps processes, too. However, in order to be a technology leader, we also need the best talent on board. In other words, employer attractiveness plays a role here. The good news is that arculus works on this every day.”