Autonomous Mobile Robots (AMRs) can significantly enhance warehouse productivity. However, selecting the right robot for your specific intralogistics needs is essential to get the most out of this innovative technology. In this blog post, we’ll share key tips to help you choose the right AMR for your warehouse.
The first step is to consider which tasks the robot will handle in the warehouse. These operations could range from transporting and sorting products to assisting with assembly workflow. The AMR you choose should be based on these specific needs. For example, while agile AMRs like arculees are a great option for underload carrier and pallet transportation, other mobile robots such as Automated Guided Vehicles (AGVs) are more suitable for vertical lifting.
Warehouse operational needs play a key role in choosing the right AMR
2. Check the Pay Load Capacity
Load capacity is another major factor when choosing an AMR. The type of materials a warehouse handles will determine whether a robot with a lower or higher load capacity is more suitable. For instance, for moving lighter items, like textiles or consumer goods, an AMR with a lower payload capacity will work best. On the other hand, a robot designed to carry high loads is a better option for transporting heavier machine parts. Matching the AMR’s payload to the product weight is crucial for ensuring smooth operations.
3. Analyse the Cost
Budgeting is an essential step when investing in a new technology, but the lowest upfront cost doesn’t always guarantee the best value. Beyond the initial price, it’s crucial to factor in expenses like maintenance, integration, software updates, and energy usage. For instance, AMRs that seem cheaper at first may demand frequent servicing or complex integrations, driving up long-term costs. Balancing these factors will help you ensure a more cost-effective investment for your business.
4. Prioritise Safety
Integrating AMRs into warehouses involves regular interaction between robots and humans in shared spaces, making safety a critical concern. To minimise risks and maintain a hazard-free environment, it's essential to choose robots that comply with safety standards like TÜV SÜD and DIN protocols. This ensures both secure and efficient intralogistics operations.
5. Look for a Scalable and Adaptable Robot
Successful integration of AMRs also depends on their flexibility. As industries evolve and warehouse needs change, robots that can adapt to new environments, navigate obstacles using sensors, and respond to real-time data are highly desirable. The good news is that being easily programable and able to accommodate fluctuating workloads, AMRs are generally scalable. When purchasing an AMR fleet, it's important to prioritise flexibility in their operations.
Different Mobile Robots serve different purposes in warehouses
6. Find a Supportive Vendor
Finally, choosing the right service provider for successful AMR integration goes a long way. When selecting a vendor, consider your specific warehouse needs and look for a partner that offers comprehensive solutions. For fully automated warehouses, a provider like Jungheinrich can supply a wide range of technologies, from AMRs to Automated Guided Vehicles (AGVs) and forklifts, ensuring seamless integration.
In Short
Integrating Autonomous Mobile Robots (AMRs) in the supply chain facilities is an effective option to support the workforce and tackle the ever-increasing demands of manufacturing. However, for maximum benefit, industries must opt for autonomous robots that are best suited to their need. To achieve that goal, companies must understand their operational requirements, research product specifications, analyse the cost-benefit ratio, and then choose the right AMR to make their warehousing processes safe, efficient, and optimal.
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:
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.
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.
Securing the Resources: Defining and integrating adequate tools for various purposes and building a motivated team to carry out the task.
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.
Thorsten Mersdorf (right) working together with Thomas Fuhrmann (left), a Software Engineer from the Brain Team
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.
Federica Granato and Thorsten Mersdorf working on the assembly of an AMR in the production area
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.”
A part of the Production Team (from left to right): Marcel Trouillaud, Jonas Jaeger, Thorsten Mersdorf, Josef Bauer, and Tamas Szipli
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.
Some of the many tools at the AMR production site of the arculus office
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:
If you want to adopt the arculee M as a solution in your facility, please visit Jungheinrich for more information.
The arculee M in the testing area of the new arculus office
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.
When developing a new Autonomous Mobile Robot (AMR) for intralogistics, deriving key lessons from the real-world use cases from the very beginning of the journey is crucial. This is what arculus did with arculee M development. In this blog post, Carlo Fitz, our Managing Director; Romano Wolf, our Product Lead for Robotics; and Iuri Ferreira, our Release Coordinator, discuss the what and how of the development process.
New AMR for Efficient Intralogistics: Goals and Strategy
Let's start with the basics. What was the goal and the development strategy for the arculee M?
Carlo: We have been part of the Jungheinrich since 2021. We began this partnership with our first Autonomous Mobile Robot (AMR), the arculee S. Since then, we have gained extensive field experience with the arculee S. We received valuable feedback from Jungheinrich's sales organisation and product and portfolio management. Based on this feedback, we developed a new product increment: the arculee M.
Romano: At the beginning of our partnership, we analysed Jungheinrich's installed base of pallet transport systems. This analysis focused on developing the arculee M specifically for pallet transportation. By examining this extensive database of installed projects, we gained valuable insights into the necessary criteria for various use cases, such as dimensions, load capacities, and other specifications.
With this information, we could precisely tailor the arculee M to meet the needs of our addressable market from Jungheinrich's perspective. This allowed us to identify the optimal specifications for our new robot and address gaps that arculee S could not fill. As a result, we expanded our market share and met the customer needs even better than before. This was our primary goal from the beginning of the development.
Can you introduce the arculee M as a system? Please explain how it's designed to play a key role in intralogistics applications.
Romano: We need to understand the arculee M as a system from two perspectives. On the one hand, there is robotics, which includes peripherals like stations and backpacks necessary for pallet transportation. On the other hand, we have fleet management, which is essential for integrating with warehouse management systems, also known as host systems. For this, we utilise a software layer from Jungheinrich, the logistics interface, which acts as an abstraction layer for our fleet management. Thus, the arculee M system encompasses all robotics components, the fleet management and the logistics interface.
Carlo: From the customer’s perspective, you get transportation from point A to point B, where the robot performs the physical tasks. However, when replacing manual transportation with automation, it's important to consider various customer interfaces. The host system manages these interfaces, determining where transportation is needed. This makes the arculee M part of a larger system with numerous software components.
What are some common pain points in intralogistics that the arculee M aims to solve? Can you give examples of how it tackles these issues?
Carlo: Logistics is a cost factor but also a crucial enabler. While transporting goods from A to B doesn't seem to add much value, having them in the right place at the right time is essential. This is where the arculee M comes in. This new AMR enables efficient transportation while minimising costs. It performs reliably 24/7, making it an effective substitute for a cost-intensive intralogistics system.
Moreover, transportation systems like conveyors were very reliable and fast in the past. However, they were also inflexible. Changing the configuration, such as the source or sink, was costly and required disassembly, reassembly, and significant infrastructure adjustments. The arculee M system, on the other hand, offers much greater flexibility. The initial setup for a project can evolve without incurring high costs.
Romano: There are several reasons why our customers want to automate. One major reason is cost. Over time, they aim to amortise their investments in optimisation, achieve scaling effects, and become more cost-effective. While cost was the primary driver in the past, recent changes in the labour market have shifted priorities. Nowadays, labour is hard to find. So many customers are driven to automate because they cannot secure the necessary workforce for manual tasks. Companies must invest in optimisation to maintain their business operations and remain productive.
Iuri, Release Coordinator at arculus, is busy working with the arculee M in the testing area
The arculee M Use Cases
What are the primary use cases for which the arculee M was developed?
Iuri: The arculee M tries to improve the solutions for underload carrier transport, meaning the arculee M would drive underneath the load, lift it, and carry it around in a plant. Its primary focus is the intralogistics, transporting goods from people to storage. This includes use cases such as narrow aisles with highly stacked items, in conjunction with other automation solutions that Jungheinrich also provides, to move goods around in parallel efficiently.
Romano: The arculee M is specifically designed for pallet transportation, particularly for Very Narrow Aisle (VNA) applications. These are high-rack storage solutions, and Jungheinrich is already a major player. We saw a significant opportunity to improve pallets' transport into these high-rack storage solutions.
One key advantage is our ability to connect two automated trucks from Jungheinrich and arculus, deploying them as a single, integrated system. However, this is just one example. Overall, the arculee M focuses on pallet transportation and can be used in various settings, such as warehouses and production facilities, where pallets must be moved from one location to another. The system efficiently picks up and shuffles pallets at designated stations.
How flexible is the new robot for specific client needs and requirements?
Carlo: The core idea was to balance these two ports. We created a physical platform with the arculee M, incorporating all the essential, complex functionalities such as localisation, navigation, and lifting activities. Based on this platform, we developed a backpack system that allows different backpacks for different load carrier types and makes the system flexible for various applications.
Additionally, we redesigned the software layer to focus on easy deployment and system robustness. This included creating a layout that minimises the number of robots used, increases throughput, and minimises deadlocks.
Romano: When we look at the market, we see a huge variety of pallets and other load carriers, and from the beginning, we aimed to stay flexible. So, how could we ensure this? We didn't want to develop a different product for every load carrier type. The idea behind the arculee M was to keep all the robotic complexity within the platform and the robot itself. Then, we created a mechanical and electrical interface for the backpack, which can be customised for different load carriers.
Iuri: This approach allows our software to remain mostly standard and basic, making testing and ensuring robustness and performance easier. At the same time, it provides the customer with the flexibility to customise the backpacks as needed, supported by the logistics interface.
The Development
Let's talk development. How are technical specifications and performance benchmarks determined for a new robot?
Iuri: When developing a new robot, the first step is to examine the market. We identify the market points we want to cover and define our target use case accordingly. We then analyse the market competition. With this information, we evaluate our technology stack to determine how we can leverage our existing capabilities to meet our use case requirements and what modifications are necessary. Navigating these modifications presents an interesting challenge. The more changes we introduce, the more complexity and risk we add to the development process, and the harder it becomes to meet deadlines.
At the end of the day, our goal is to create a high-performance robot that maximises throughput for the customer. So, there's always a fine line between further increasing robustness and stability while minimising risks and bringing a good product to market.
Romano: We call what Iuri just mentioned the platform approach. Our strategy involves developing products vertically, meaning we have access to all platform components ranging from the high-level software layer to the low-level software running on a dedicated microcontroller.
When we develop a new derivative, we first examine the use cases to identify relevant requirements and product specifications. Based on these insights, we can adapt and scale our platform as needed. This might involve adding peripherals or sensors or modifying the physical aspects of the platform. These changes could be in mechanics, electronics, or software.
The key advantage of this approach is that it is always based on our existing platform and expertise. This allows us to efficiently scale our platform to meet the new use case we want to target.
Carlo: The goal is to create a minimum viable product (MVP) with specific features that can be brought to market quickly. This will allow us to gather customer feedback and understand the market demands. From there, we will iterate on the product, refining it based on real-world data.
Initial ideas for a product are based on hypotheses. It's crucial to test these hypotheses early in the process to validate or correct our assumptions. This helps us determine if our initial market hypotheses are accurate. Through this iterative approach, we can evolve the MVP into a final product that effectively meets market needs.
The Evolution from S to M
Finally, let's talk about evolution. How does the arculee M signify an evolution from the arculee S regarding functionality and benefits?
Romano: For the arculee S, we initially targeted table transportation. At that time, we had major projects in warehouse applications, and transporting tables from point A to point B was a common task. This was the primary purpose of the arculee S. However, after Jungheinrich's acquisition, we discovered the field of pallet transportation. Our first project in pallet transportation was done using the arculee S, and it was successful.
However, despite this success, we encountered limitations as we brought the product to market, particularly in scaling up load capacity and height. When reviewing potential new projects, we noticed a gap in our portfolio—we couldn't handle higher load requirements. This realisation led to the development of the arculee M. It was designed to close this gap and accommodate higher load capacities and greater load heights, addressing the limitations of the arculee S for the pallet use case.
Iuri: The improvements don't stop there. As we discussed earlier, robotics is a dynamic, evolving field. Based on field feedback, we significantly improved the robot's serviceability. We focused on how easy it is to provide service and maintenance. The robot includes several critical safety features that must be tested annually. With this in mind, we made changes to simplify the service process for technicians, ultimately reducing costs and enhancing the overall product.
Romano: Specifically for the arculee M, we divided the product into several submodules, such as the lift, active lift, passive lift, electronics module, and peripherals. This modular approach makes the robot easier to assemble, significantly reducing production time. Additionally, it simplifies maintenance, making it easier to access, service, and replace components. Achieving these goals has been a significant success for us.
Due to its optimal performance, the arculus Robot Control Unit (RCU) was retained from arculee S into the arculee M.
How has field experience from the arculee S shaped the development of the M model?
Carlo: The arculee M inherited many core ideas from the S. For example, we retained the central Robot Control Unit (RCU) in the arculee M, which we developed for the S. The RCU is a closed electronics unit that incorporates all the key electronic features needed to create the robot's autonomy layer. However, for the improvements, in addition to focusing on load capacities, we concentrated on enhancing localisation and navigation capabilities, putting significant effort into software development in these areas for the new robot.
Romano: Looking at the arculee S and its components, we learned from field experience which components worked well and which posed challenges due to supplier issues or performance. We applied these lessons to the arculee M. We kept or adapted the components that performed well while we upgraded components where we have seen potential for improvements. This included enhancements to actuators, sensors, and software.
This is all about how focusing on particular use cases improved the development of the arculee M. Watch the complete interview below!
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.
Fabian Na, Senior Mechanical Design Engineer at arculus, discusses the various aspects of the arculee M mechanics
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.
Testing a product at different stages of development is crucial for improving the mechanical design
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:
Cost
Time
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.
Linus, Product Owner at arculus, explains that the mechanical complexity decisions differ depending on the AMR’s development stage
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.
The arculus RCU®, designed for arculee S was also adapted for the arculee M
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 harness wire spools at the electronics labs
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.
Andres and Jolly are busy working in the arculus electronics lab
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.
Tobias explains the importance of functional safety when making design and electronics decisions for an AMR
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.
The spacious testing area at the new arculus’ office
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!
One mission of arculus is to bring the best technology to the world of intralogistics through continuous innovation and development. The new arculus Fleet Management Software is just another example of this dedication. This blog post explores the key features of the latest generation of our Fleet Manager and how it makes the user journey easier, as discussed by Georg Held, Senior Product Manager, Andy Brinkmeyer, Software Engineer, and Axel Jäger, Teamlead Frontend Development at arculus.
The Basics of the arculus Fleet Manager
Let's discuss the basics. Can you provide an overview of the features in the new software?
Georg: Yeah. So, the arculus fleet manager consists mainly of three feature domains: the layouter, the simulator, and the operator. We provide the user with a layout editor and a layout manager so that they can create their project in the software. The simulator helps to set up a transport matrix and to simulate on the created layout, making it easier to understand the performance of a certain project. The operator is where the fleet manager handles all the arculees (our AMRs) and controls traffic.
What fundamental changes did you apply in creating the new generation of arculus fleet management software?
Georg: The user journey of the product was very important to us. We had a fleet manager already in the market in some projects. Considering our experience from those previous installations and from the customers who were using the software, we conceptually created a new fleet manager. The idea was to have one tool for the whole user journey from presales to operation by a coherent user interface. Perhaps Axel can provide more detailed insights here.
Axel: Yeah, an issue we had with our previous product was that when the user made some change, like creating an additional drive, and then checked the actual impact on the system, it seemed to take a long time to actualise. Now, for the new generation of the product, our goal was to make this as fast as possible. For example, you can immediately see the effect if you change something now. So you can run many iteration cycles in a shorter amount of time and find the best-performing layout.
Georg: And just to add on to that—actually, I'm among those user groups that greatly benefit from the new fleet manager because, in our test area, I am now able, to set up a test project within 30 to 45 minutes. I no longer need support from the development teams, which makes my work easier and allows the experts to invest their energies in other tasks without worrying about software usage.
Georg, explaining what makes the new arculus Fleet Manager user-friendly
arculus Fleet Manager: The Technical Aspects
Moving to the technical topics, how does the user interface of the fleet manager facilitate ease of use, especially for the various user groups and complex operations?
Axel: The first step a user typically takes is to create a representation of the shop floor. You can either do it by importing data from a CAD system, especially for a new factory building, or by using a robot to scan the existing environment. Once you have the shop floor layout, the next step is to place various objects onto it, such as driveways, stations, and other necessary features. For the user, the primary goal is to define the essential components of the factory or warehouse.
We aim to simplify this process as much as possible, ensuring the user's intentions are easily captured. Then, for our internal representation inside the fleet manager, we convert the user input to a data structure that the robot can use.
Andy: Also, a key part of our system is ensuring that once a layout is validated, it works seamlessly without requiring further adjustments. When the user creates a layout, we run all necessary checks. If there are any issues, we inform the user about what they need to correct or modify. However, once the layout passes validation, it should function perfectly right away. The user shouldn't need to make additional tweaks, for example, to prevent collisions or vehicle blockages.
Georg: In addition, one of our main goals, especially during this initial development phase, is to test the product with end-users. This means we develop the features Axel described, test them with users, see what works well and what doesn't, and then make improvements accordingly.
How did you decide on the technology stack and architecture for the new fleet manager?
Andy: Perhaps let’s talk about the backend first - this is the part where we do all the complex algorithms, logic, and communication with vehicles and other connected systems. So, here we focused on what's most important to our customers - reliability and robustness. No one wants to be woken up in the middle of the night because of a crash or have an entire shift blocked at some logistics centre due to any unexpected software issue.
In addition to robustness and safety, we prioritised performance since we are also targeting large fleets, potentially over 100 vehicles. We've successfully tested this in simulation, and it works like a charm! To achieve this, we built our backend on Rust, an emerging language that mainly focuses on safety and performance.
Axel: So, we have a web-based system for the front end. It is good because:
We can then utilise the richness of a web-based frontend ecosystem
It allows us to deploy the software on one server and access it with every client
Talking of the more specific technology stack, we went for a combination of angular, which is a Single Page Application (SPA) framework provided by Google. On top of that, we installed a 3D engine which has the potential to show a realistic digital twin of a facility.
Georg: The tech stack the team selected can run on standard business computers, such as mine, allowing me to test and verify our system. This also assures me that it will work on standard customer computers, which is crucial given the strict IT regulations our customers usually have. Therefore, our technology choice was influenced not only by detailed engineering decisions but also by market standards.
Andy believes that using Rust as the main language was one of the best decisions the team made for their tool stack.
Were there any particular tools or frameworks that proved to be pivotal?
Andy: Coming from the world of systems programming, where languages like C++ and C are common, I know there is often a lot of overhead with tooling to get everything built and running. So, for me, choosing Rust as our main backend language was the best decision for our tool stack because it provides comprehensive solutions, eliminating the need for additional tooling for building and dependency management. It’s part of a robust and growing ecosystem, simplifying our development process and integrating well with our systems.
Georg: Well, I have one anecdote to share about this. So, Rust as a development language was also quite new to the team, and when we initially introduced it, one team member said that they would never learn it due to its conceptual differences from what they were used to. However, just two or three weeks later, those concerns vanished. It turned out to be surprisingly easy to onboard the team to Rust.
What is the role of VDA5050 in the new software? What benefits does it bring to users?
Andy: VDA5050 is a crucial part of our system because it's a specification that outlines how a fleet management system should communicate with a robot. A lot of big companies have developed it together to specify how this should look. We at arculus also contribute to the development of the specifications, and it helps us in multiple ways.
Defining Communication Standards
Firstly, it streamlines the process by defining communication standards, eliminating the need to devise our own protocols. With the adoption of the new fleet management system, we've phased out our legacy communication protocol in favour of VDA5050.
Interoperability
Additionally, VDA5050 enhances interoperability. As an industry standard supported by various developers of fleet management systems and robots, it allows our system to interface with a wide array of different robots. This flexibility benefits our customers, who have the option to use our fleet management system with diverse robot models. Conversely, our robots also support VDA5050, ensuring compatibility with alternative fleet management systems if a customer chooses to switch.
Axel: Usually, when we supply such an automation system, it's not a greenfield project. Instead it is an integration into existing setups and processes. So we contribute some parts of it and establish interfaces with other parts of the factory floor. Sometimes, we even encounter mixed traffic. And, of course, if we have our fleet manager with our robots, we can nicely visualise them on a canvas. However, there are instances where one of our vehicles cannot operate due to the presence of vehicles from different vendors or systems serving different purposes.
To ensure transparency for users and explain why a specific vehicle is not moving, we must visualise all vehicles. This also includes the ones that are not under our direct control. VDA5050, being a standard communication protocol, enables us to access information from all vehicles across the factory floor. Moreover, it facilitates better decision-making and system management.
Providing an immediate response to a user command is one of the priorities for the new arculus Fleet Manager.
Performance Optimisation of the New arculus Fleet Manager
Let's talk performance. What strategies were employed to optimise the performance of the new fleet manager, particularly in handling large fleets in complex environments?
Andy: One of our primary goals in developing the fleet management system was to ensure it could support large fleets exceeding 100 vehicles. So, we decided to employ modern algorithms right out of the academic world. These work on a detailed level by subdividing space into smaller regions. Unlike our competitors, our system doesn't just check where we are driving; it also considers possible future scenarios of vehicle locking and congestion.
This approach sets us apart in the industry, as we're among the few working with this foresight. Of course, we had to adapt these algorithms from academia to suit real-world complexities. Fortunately, initial simulations have yielded promising results as we've successfully controlled a fleet of 150 vehicles on potential layouts.
How does the Fleet Manager’s backend handle real-time data processing and decision-making?
Andy: That’s a great question! For a fleet of robots driving around, you don't have much time to tell them what to do. If they don't get another command, they will just keep standing there. The robots will not process any order, and will not deliver any material. So we need to react fast. From the operational side, we do that with:
Our modern tech stack, which, combined with our algorithms, allows super-fast processing and decision-making
VDA5050 communication protocol that helps us directly communicate with the robot and send updates as quickly as possible
However, the robots also generate a lot of data while driving around and operating. This data can then be used to further evaluate, monitor, and determine what to do next in real-time.
Georg: When you deal with real-time data, you have to think about what this really means. What do you think, Andy?
Andy: Yes, it depends on the type of data you're looking at. For instance, in terms of visualisation, which is Axel's department, the robot sends updates multiple times per second. However, other parts of the communication are more event-driven. For example, if a robot gets clearance to drive to a specific location, it passes certain waypoints along the way. It updates us when it reaches a certain waypoint, saying, "Hey, I reached it." This allows us to run additional logic, potentially change something, or simply command it to continue driving.
Georg: That's great input, and this is exactly what I meant earlier. You need to create several abstraction layers to effectively handle and expose the relevant data to users. I mean, the data acts as a digital twin of the site—whether it's a warehouse, factory, or another facility. It shows what's happening in real time. You can iterate how crucial it is to process and then present the data to the user if we want to display the state of a robot, its battery level, its current location and its route.
Axel, perhaps you can expand on this since, as you already mentioned, the layout canvas and how it works.
Axel: Yeah, this is definitely important from the user's perspective. When you give a manual command to the robot, such as: ‘drive to a location’ or ‘head to a charging station’, you would want to see immediate feedback. However, the robot has to perform several actions before it can start moving, such as switching sensors and releasing brakes. If you're near the robot, you can hear these actions and know there is a response. However, if you're at your computer, every fraction of a second of delay matters.
Now, feedback within several hundred milliseconds would be acceptable. However, if it takes several seconds, the user will perceive the system as sluggish or broken. While it's nice to have an animated UI, it's crucial the system provides immediate and clear responses to initiated actions. This ensures the user’s trust in the system.
This is all about the arculus Fleet Management Software. Watch the entire video below!
From working student to full-time Electronics Developer, Andres Magallanes began his journey at arculus in 2018, and now he is responsible for the electronic designs for our current robot portfolio. Andres is part of the first arculee generation and has since grown personally and professionally with the company. In this article, you will have the chance to hear about Andres’ individual and skill development story with arculus, along with his advice for future applicants.
Hi Andres. Thank you for joining the interview! Please tell us a little bit about yourself.
Andres: "I come from Mexico. I have always been interested in electronics and embedded systems. It has always been my dream to work in development abroad, and with this in mind, Germany seemed a very attractive option. So, after completing my Bachelor's degree in Mechatronics Engineering, I decided to come here and pursue my Master's in Automotive Engineering. That was when I first heard about arculus."
Can you share your time as a working student at arculus?
Andres: "I was part of the embedded and electronics team in the early years of arculus. I was in charge of various electronic tasks, from designing and prototyping the harness and PCB to electrical debugging, testing and documentation. I also covered some programming tasks, for example, for the microcontrollers. Although I was new to the tasks, I had a firm grasp of the basics. I took on the challenge of self-learning and quickly became proficient. My proudest moment was supporting the electronics topics of the first arculee generation!"
Andres working on the RCU
As an Electronic Developer, how has your role evolved over the years?
Andres: "Now, my role has transitioned to electronic-specific tasks without any programming involved. I still cover many of the tasks from the beginning, and with the company growing, new teams now cover the remaining tasks. For example, as an electronic engineer, I am currently responsible for:
The design of new PCBs: This includes starting with the CAD design in Altium and taking care of prototyping (which may include the inhouse assembly), testing, debugging and implementation of changes to the design
The creation of the electrical documentation for all our robots/backpacks: These are the connection diagrams that show how all the components are interconnected inside the robot/backpack and are also the base for the harness design in the 3D CAD software
Supporting the harness design: This task involves communicating with suppliers and testing the supplied harness prototypes. It also includes handling the in-house build-up of harnesses for test benches and backpacks.
Supporting the robot production with electrical/electronic solutions: This task covers debugging issues and repairing damaged components or wires.
Moreover, during the arculee M production, I was mainly in charge of creating the electrical diagrams that would later be used to generate the harness production data. I was also a part of the harness design and prototype testing, where we found, fixed, and documented issues along with points of improvement for the supplier.”
You were part of the early days of arculus; how has the workplace changed since you first started?
Andres: "The team has grown a lot yet still embraces the same culture of diversity and friendly environment with lots of team-building activities. Structurally, the company has become more established since its startup origin. Lastly, we have the new office that has made work more fun!"
In what ways has arculus supported your personal and professional growth?
Andres: "It is a great experience to work with so many different people from many parts of the world; you can learn a lot from them personally and professionally. As a company, arculus allows me to develop something new within electronic design and work on further improvement with every new generation of robots. I highlight two specific skills I have acquired here: programming for embedded systems and harness design. Furthermore, arculus also provides access to training when required."
Andres, in a discussion with a colleague from the electronics team
Lastly, what advice would you give someone interested in starting their career with us?
Andres: "Definitely, be prepared to meet some amazing colleagues! My experience here has shown me that with the right support groups, such as the one we have here, you can embrace new experiences with confidence. With arculus, I can promise some challenging but also fulfilling days."
This is the story of Andres, from a passionate student to a proficient electronics professional. If you're also eager to embark on a challenging yet rewarding career path in electronics development, then arculus is the place for you. Apply today and join Andres and many others in shaping the future of automation!
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.
Thorsten and Diego at the production area ensuring the arculee functions properly
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.
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.”
Thorsten and Federica working on an arculee S
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.”
In today's fast-paced business landscape, speed and efficiency are crucial for success. However, many companies struggle with the challenges of bureaucracy, which can lead to bottlenecks in development and slower product releases. In this blog post, Max Stähr, Head of Technology at arculus, delves into the strategies and practices that enable us to achieve remarkable development speed and maintain a flexible and responsive approach to meet evolving market demands.
Need for speed
Speed and efficiency: two words often linked to the German Arbeitsweise (way of work), reflecting a vision many strive for in the business world. However, the reality is far from ideal, as many companies deal with the effects of excessive bureaucracy. The results can be devastating – from missed market opportunities to overlooked consumer needs. That’s why fast and efficient development is especially important in today’s business landscape.
In recognising this, arculus understands the limitations of long-term planning in a rapidly evolving market. Long-term strategies can be constrained by assumptions that may soon become outdated. Thus, we focus on an adaptable, short-term approach that allows for quick responses to market changes. This method enables us to develop efficient robotic and software products, that are not only fast and sustainable but also flexible enough to adapt to immediate market needs, and feedback, steering clear of rigid, industry-specific models.
Thanks to a management team that understands the importance of efficiency, we can implement innovative strategies that make our development speed our greatest strength. This has been a part of our company DNA since the beginning, but the most recent example is the arculee M. It took our team less than 12 months to bring it to life: from idea to the final product.
Two arculee Ms in action at a warehouse
Here is how we do it
Our secret to fast development lies in several basic strategies and practices. First and foremost, we prioritise a straightforward development cycle. By reducing unnecessary steps in the process, we can promptly roll out the product right after we’ve completed thorough testing. This process allows us to receive valuable feedback from the market, directly enabling our product managers to generate new ideas and optimisations that reflect real customer needs.
For instance, the development of the arculee M was a direct result of our market research and customer insights. The need for an evolved product was clear from the feedback on the arculee S, as customers were looking for enhanced features – like a higher load capacity. With a streamlined development cycle, our team was quick to respond, ultimately bringing a new robot to market in record time. This is mirrored in the evolution of our fleet manager, which has been similarly upgraded to a new version that reflects our proactive stance in keeping up with the dynamic needs of intralogistics through improved functionalities.
Our approach to product design
Building on the insights gathered from our market research and customer feedback, our approach to product design has been instrumental in rapidly evolving our solutions. Years ago, we made the strategic decision to build products in a way that allows us to reuse components across different hardware models. This method also enables us to seamlessly integrate new software into our hardware products, breaking the link between software features and specific robot models.
The main example of this concept is our Robot Control Unit (RCU®), which we consider to be the “electronics heart of our robots.” It serves as a core component that can be effortlessly swapped between our two current robot models, the arculee S and the arculee M. This flexibility simplifies our development process and significantly reduces the time and effort needed to implement robotics software for new iterations of hardware products. Moreover, it provides us with the necessary resources to continuously add new features and improve the quality of our solutions – rather than being bogged down by redundant, product-specific tasks. By avoiding the need to “reinvent the wheel” with each new release, we can scale our solutions more effectively, ensuring a steady enhancement of our portfolio.
The role of Scrum
Another element of our speed development is the use of Scrum, which allows us to break down complex tasks into manageable iteration cycles, typically known as "sprints.” During the 2-week sprints, each team has clear goals and focuses on specific tasks, encouraging a sense of urgency and collaboration. This way, our developers actively engage in direct technical exchanges with one another, ensuring that everyone is aligned and informed about project progress.
Rudolf Guth (Engineering Manager and Scrum Master) during a Sprint Retrospective session with the mechanics team
For all of that to work, we ensure that our developers maintain direct technical communication and rely on flat hierarchies. The result is shorter decision-making processes and faster cross-team coordination. This environment fosters a strong sense of individual responsibility and motivation among team members, all contributing to our ability to achieve rapid results in product development.
Flexibility as a consequence
I’ve already briefly mentioned some of the benefits of fast development: staying competitive, meeting customer expectations, and keeping up with industry changes. However, one advantage that deserves special attention is the flexibility that comes with our rapid development process.
By rolling out hardware projects in approximately 12 months and software increments in just four weeks, we are able to collaborate closely with customers. This allows us to tailor our products to their specific needs during development and easily respond to market changes and trends. We recognise that not every feature is universally applicable, emphasising efficiency, safety, and cost-effectiveness over short-term industry trends. By leveraging our developers' capabilities and focusing on genuine demand, we maintain a flexible approach that allows us to offer customised solutions.
Full stack concept
An important addition here is that to actually solve customers’ pain points, we established a company culture of delivering not products, but full-stack solutions. This means our offerings extend beyond advanced Autonomous Mobile Robots (AMRs); they include an integrated fleet management system that ensures a cohesive and streamlined approach to intralogistics.
For that, we rely on a constant evaluation of key performance indicators (KPIs) such as “'jobs per hour” — a metric that directly reflects our robots' efficiency. By rigorously assessing our efficiency and competitiveness, we can ensure that our speed in development translates into real-world effectiveness and value for our clients. It's this dedication to measurable results and continuous improvement that differentiates us from competitors, cementing our status not just as a provider but as a business partner for intralogistics automation.
Members of different teams at arculus working together on a software-related task
What you should take from this
At arculus, we are proud of the efficiency standards we’ve achieved for development. However, we do recognise that there is always room for improvement, and we are dedicated to continually refining our processes and seeking new ways to enhance our capabilities. Our goal is not just to maintain our current patterns but to consistently raise the bar and adapt to the evolving needs of our customers and the ever-changing landscape of our industry.
With all that said, I strongly believe that our straightforward approach can serve as a leading example in our field – and the development of the arculee M in record time is a testament to that. We prioritise a simplified development cycle, allowing us to promptly roll out products, gather valuable market feedback, and generate innovative ideas for optimisation. Our unique product design approach reduces development effort and enhances flexibility. Coupled with Scrum methodology and flat hierarchies, our culture of continuous improvement ensures we remain flexible and responsive to market demands, making us well-equipped to tackle the challenges of the future.
With continuous technological advancements, robotics is becoming more innovative and efficient. As a result, using robots is now indispensable to ensure ample productivity and market competitiveness for various industries. From Autonomous Mobile Robots (AMRs) navigating around a warehouse to domestic robots assisting people with tiresome house chores, these machines come in different sizes and shapes. This blog post covers the numerous types of robots and their respective uses in detail.
The sources say that the world was home to a whopping 3.4 million robots in 2023. And that was just the number of industrial robots. Many other types are not even accounted for. The reason behind this surge is their efficiency and productivity, which, in turn, comes from their specificity and precision. Being specific means there are particular robotic categories, each performing an intended task. Knowing the various types of robots and their functions is thus crucial for optimising efficiency, driving innovation and making the most of this technology.
What Types of Robots are There?
There are several ways to divide robots. The following classification uses their application, degree of movement, and autonomy as the distinguishing factors.
5 Types of Robots Based on Application:
Robots serve many purposes, and categorising them based on their applications provides valuable insights into their functionality.
1. Industrial Robots
The manufacturing industry has been using robots for various processes, such as assembly, welding, and transportation, for many years. Recent advances in robotics have increased the usage of industrial robots as they ensure on-site safety and more productivity in businesses.
Examples of industrial robots: Robotics arms or articulated robots are great for expediting manufacturing processes like assembly and welding as they work fast and precisely from a fixed spot. Meanwhile, Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs) are more suitable for transportation and warehousing due to their mobility and navigation capabilities.
Our arculees at work inside a warehouse
2. Medical Robots
As the name indicates, medical robots are advanced machines performing different functions in the healthcare industry. Reports suggest they help increase precision in surgeries, efficiently disinfect hospitals, and deliver medicines and meals. Furthermore, humanoid social robots offer support to rehabilitate patients after trauma or surgeries. For example, robots communicate and nudge patients to take their medication on time.
Examples of medical robots: Surgical arms help doctors with high-precision surgeries, automated disinfection systems take care of disease-infested areas to ensure the safety of hospital staff, patients, and visitors, and wearable exoskeletons increase accessibility for disabled people, allowing them to lift heavy objects and move more freely.
3. Domestic Robots
Domestic robots come in handy for floor cleaning, laundry, security/surveillance, and cooking. They are also in demand to provide companionship to older people and help them live more independently. For example, home robots not only take care of the household chores for older people but also greet them, talk to them, and even offer cognitive stimulation through games and other related activities.
Examples of domestic robots: Vacuum cleaner robots clean the floors, while some autonomous robots can wash and fold laundry. They take the burden of home management off your shoulders so you can prioritise other things, such as spending time with your friends and family without burning out.
4. Service Robots
This broad category comprises all kinds of robots assisting humans. The main idea behind service robots is to help humans with their work and ensure a better consumer experience. Thanks to their utility in performing various tasks, like valet parking, food delivery, and concierge services, there has been a tremendous increase in their demand since 2016.
Examples of service robots: Concierge robots at hotels deliver food and utilities to rooms, reserve tours and restaurants for guests, and retail service robots provide helpful information to customers.
5. Entertainment Robots
All robots accomplish a specific job, but then what about the ones that are only there for the sake of fun? Well, their purpose is to provide entertainment. So, they are programmed to do certain routines like dancing, singing, and speaking to please an audience. You will find them more commonly in amusement parks and haunted houses to offer thrill and adventure, in trade shows for promos and marketing purposes, and as toys for kids.
Examples of entertainment robots: Toy robots interact with the environment and the kids to increase their creativity and imagination, robotic dogs offer companionship, humanoid entertainer robots suitable for parties and events, and promotion robots.
2 Types of Robots Based on Mobility:
Another way to classify the robots is by their degree of movement:
1. Mobile Robots
Mobile robots are automatic machines that use sensors and other technology to identify and navigate their surroundings. These include Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs). While AGVs move along a predetermined path, AMRs travel autonomously.
Examples of mobile robots: AMRs such as arculees and AGVs like Jungheinrich EKS 215a find extensive use in warehouse automation by ensuring safe and efficient transportation.
Jungheinrich Mobile Robots for warehouse automation
2. Stationary or Fixed Robots
In contrast to mobile robots, stationary robots work from a fixed location. They are more suitable for high-precision tasks like welding, assembly, lifting, and insertion. The manufacturing industry heavily employs different types of fixed robots depending on the nature of the required job.
Examples of stationary robots: Companies often use Cartesian or Gantry robots for lifting and assembling components as they offer fast and efficient linear movement and Selective Compliant Assembly Robot Arms or SCARA for insertion tasks due to their flexible movement in the XY-axis but rigidity in the Z-axis.
TL;DR
Robotics has evolved to engineer innovative automatic and autonomous machines with numerous applications. These robots can be either mobile or stationary, depending on their degree of movement. Based on their application, they can also be domestic, industrial, medical, service, and entertainment robots. Many types overlap, and the choice of robot eventually depends on the task at hand.
The conclusion? Ongoing advancements in robotics promise a future where robot applications will continue to evolve and diversify, opening doors to more innovation and possibilities.
