November 30, 2023

Intralogistics 4.0: Demystifying The Potential of Advanced Warehouse Management

The fourth industrial revolution has transformed the vocabulary of all business processes, including Intralogistics. Terms like automation, artificial intelligence, and the Internet of Things (IoT) have also become the norm for the supply chain industry. Aptly called Intralogistics 4.0 (I 4.0), this reformation in warehousing is greatly connected with the technology of Autonomous Mobile Robots (AMRs). Since arculus contributes to this development with its own AMRs (arculees) and software, it is only fitting to take the discussion to Carlo Fitz, our managing director. This blog post uses his expertise and insights to unravel the promises, myths, and challenges surrounding I 4.0.

Unpacking Intralogistics 4.0

A tale of four revolutions

The Industrial Revolution has seen different phases, each more remarkable in terms of enhancing efficiency, speed, and productivity. Thanks to steam power, the first wave came in the 18th century, literally taking production from human hands to machines. The 19th century saw the second industrial revolution (Industry 2.0). Advanced by electrification, this stage gave way to mass production within the industry. Meanwhile, the third step, the digital revolution, resulted from the development of silicon microprocessors in the late 1970s and paved the way for increased automation. Finally, we have the latest period of innovation, called Industry 4.0 - distinguished from the previous stages through such advancements as the Internet of Things (IoT), artificial intelligence (AI), and data analytics.

I 4.0: from industry to logistics

Like many other industries, logistics has flourished alongside each industrial advancement, thus benefitting from faster and more efficient solutions to the demands and challenges of warehousing. This follows for Industry 4.0, which has made Intralogistics 4.0 possible.

Intralogistics 4.0 (or I 4.0) uses the latest developments of Industry 4.0 to optimise and streamline internal warehouse processes. Representing a new era in industrial operations, I 4.0 aims to cater to the demands and challenges of the modern supply chain. In the words of Carlo Fitz, Managing Director at arculus, “Intralogistics 4.0 is about integrating advanced digital technologies and data-driven approaches within intralogistics.”

Understanding the terms and techs

Since Intralogistics 4.0 derives inspiration from the concept of Industry 4.0, it relies on some key components and technologies of the latter. These include:

  • Internet of Things (IoT): for ensuring connectivity of the devices in warehouse and logistics operations;
  • Big data analytics: for extracting valuable insights from large, complex datasets within the intralogistics system;
  • Automation and robotics: for improving speed, accuracy, and reliability of intralogistics processes;
  • Artificial Intelligence (AI): for intelligence, adaptability, and automation of the internal warehousing procedures within warehouses and facilities;
  • Cloud computing: to provide scalable, flexible, and connected infrastructure for various applications and services within warehouse and internal logistics operations;
  • Augmented Reality (AR) and Virtual Reality (VR): to enhance visualisation, training, and human-machine interaction in warehouse and internal logistics operations.

Consequently, adding such state-of-the-art technologies to warehousing management can tap into the true potential of the intralogistics industry.

arculus employee using a laptop to incorporate the technologies of Intralogistics 4.0 into the warehouse processes
arculus incorporates I 4.0 to automate warehouse processes

The potential of Intralogistics 4.0

As mentioned before, Intralogistics 4.0 (I 4.0) can substantially impact the modern industrial landscape. Carlo emphasises these five advantages:

  • Enhanced efficiency: Through leveraging real-time data and automation, Intralogistics 4.0 optimises processes to reduce delays, errors, and manual intervention, resulting in increased operational efficiency and throughput;
  • Cost savings: Improved efficiency, reduced waste, and better resource utilisation contribute to significant cost savings over time;
  • Agility and adaptability: With data-driven insights, businesses can respond promptly to changes in demand, market trends, or disruptions in the supply chain;
  • Competitive advantage: Implementing I 4.0 solutions can differentiate companies by enabling faster order fulfilment, higher accuracy, and improved customer satisfaction;
  • Sustainability: Optimised operations result in less energy consumption and reduced environmental impact.

Since I 4.0 has so much to offer, it is only natural that companies working to shape the future of intralogistics should explore these new advancements. So it is no wonder that Jungheinrich, with its years of transforming the world of logistics, is at the forefront of the I 4.0 revolution.

Jungheinrich - the intralogistics pioneers

With its aim to provide efficient and sustainable intralogistics management, Jungheinrich explores and utilises the advancements of Industry 4.0. One way it does this, is through arculus. The aim is to offer effective assistance to customers on their supply chain journey. For that, arculus engineers, automates, and enhances the latest technologies to create warehousing solutions that are customised according to the logistical needs of our clients.

Offering efficient transportation of material in warehouses, arculees, our Autonomous Mobile Robots (AMRs) lead the cycle of logistical procedures. Carlo describes these products of ingenious robotics as “flexible, dynamic, and adaptable.” However, this is just one way in which I 4.0 is implemented.

Carlo believes, “To play to the full potential of I 4.0, we need to transform every step of warehouse management.” Therefore, we also offer cutting-edge software that executes intelligent and real-time decisions on-site, which is the essence of I 4.0.

While these Intralogistics 4.0 innovations offer automation and speed, safety is crucial for long-term implementation. Besides, safety always comes first at arculus. Carlo explains, “We cooperate with the Technischer Überwachungsverein (TÜV) regarding certification. This means we always use the highest standards regarding human safety while challenging how we develop and interpret norms and regulations.”

arculee, an Autonomous Mobile Robot (AMR) by arculus is carrying goods at a warehouse
One of our arculees in action

Getting the facts straight

With a revolutionary field like Intralogistics 4.0 comes great misconceptions, often with greater consequences. Carlo points out two such misunderstandings concerning I 4.0:

I 4.0 is just about replacing people with machines: Many people, sometimes including solution providers, believe that implementing I 4.0 is just about having one machine do the work of many humans. Unfortunately, assumptions like these may mean underplaying the value of the human element in offering innovation and enhancement. The truth is, a more practical application would only be possible through human intervention. Otherwise, relying solely on machines could result in poorly designed automation, inaccurate expectations, and a lower ROI than I 4.0 could deliver.

I 4.0 is just about adopting the latest features: Even when industries pay attention to updating the systems, they may focus too much on bringing the latest tech on board, and sometimes ignore other equally important aspects of I 4.0 integration. For example, the reliability and cost-efficiency of the systems are likely to be compromised if advanced tech is the sole priority. Again, this can sacrifice efficiency and productivity, undermining the true potential of I 4.0. Therefore, while driving innovation through technology is essential, the right balance between the latest features and robustness must be considered for around-the-clock operations.

Wise advice

To avoid falling prey to myths and inefficient practices, companies adopting Intralogistics 4.0 and AMR technologies should be careful. To maximise the benefits and minimise potential challenges of I 4.0, Carlo recommends the following:

  • Conduct a thorough needs assessment: Understand your specific operational challenges, goals, and constraints. Identify areas where I 4.0 and AMR can make the most impact.
  • Start small and scale up: Begin with a pilot project in a controlled environment to test and refine the technology. Once proven successful, gradually expand its application.
  • Integrate with existing IT infrastructure: Awareness of the existing IT infrastructure is essential. The knowledge of the company’s capabilities and needs, helps create a better environment for a successful execution.
  • Rethink processes: Automation and digitalisation not only means replacing manual actions. Re-designing existing methods to leverage the full potential of I 4.0 and AMRs is also pivotal.
  • Listen to your workforce: The employees play a critical role in any successful implementation. Their concerns regarding automation and new technologies need to be anticipated and addressed. Effective management in this regard can help alleviate fears and resistance.
Jungheinrich employees assisting customers with the use of Autonomous Mobile Robots (AMRs)
Jungheinrich After-Sales works hard to help customers incorporate Intralogisitcs 4.0 technologies

The future and challenges of Intralogistics 4.0

Despite its popularity and usefulness, I 4.0 still has a lot of room for improvement and advancement. According to Carlo, “The future development of Intralogistics 4.0 will be towards consolidation and finding ways to implement it on a big scale - thus, making standardisation crucial.”He also further emphasises the importance of having a uniform standard in intralogistics and talks about its challenges:

“Remember how videotape formats such as VHS and Betamax had created a demand for standardisation in the past? So whenever there are different approaches to a solution in the market, regularisation will be needed. Unfortunately for intralogistics, this road to creating protocols is a lot more complex than just devising a format. Of course, VDA5050 is the first step towards standardising Intralogistics 4.0. However, there is still a long way to go before we have protocols necessary to scale the potential of I 4.0 and ensure reliability while reducing costs across industries.”

Concerning the possibility of entering into Intralogistics 5.0, Carlo expresses confidence in the current phase instead:

“I think we have only scratched the surface of the full potential and opportunities Intralogistics 4.0 has to offer. While we are currently making progress, there is still much industrialisation to come. With that, I believe the next phase is still a topic for the distant future.”

November 27, 2023

This Is How We Improved The Technical Knowledge of New Joiners

Meet Iuri, our release coordinator in robotics and one of arculus's pioneering members. In this blog post, join Iuri as he shares firsthand the journey of leveraging his extensive product and company knowledge to enhance the onboarding experience for our new joiners. From introductory rendezvous to delving into Linux classes, discover how he transformed our members’ communications, expertise, and sense of belonging.


arculus has very diverse teams. Ranging from commercial and content, through web and cloud, to mechanics, electronics, service and production — to name a few. And, just like our teams, our solutions are very broad in spectrum. This makes onboarding new team members quite a challenge: the new employee needs to know about the product to be able to perform best at their new job, but the learning curve is very steep.

Screenshot of a videocall showing four people waving to the camera
Our summer 2023 new joiners

How it all started

Six years ago, when I joined the company, not much had been developed. Onboarding was quite straightforward: a colleague would sit with you, and in half a day, you would have all the knowledge needed. Since then, many more products, processes and technologies have been developed and introduced. Understanding them and the reasons why certain decisions were made is key for a new joiner to best contribute to the company.

Such an understanding can be passed on to new employees by allowing them to know the technologies and motivating them to ask questions. To achieve that, and in an attempt to give new joiners the best opportunity to grow into the company and deliver their best work, I came up with introductory training courses. Every few months, I will dedicate a week to preparing, organizing and presenting the courses. The goal is simple: ensure that everybody knows enough about our products to excel at their job.

The courses

Initially focused on our production team — responsible for producing the robots — the training courses guide the trainees, step by step, through the different levels of complexity of our AMR (Autonomous Mobile Robot). Starting with the basics in the course arculee rendezvous, the new joiners receive safety instructions, as well as information about robot operation and functionality. A robot is always available on-site so that newcomers can test it for themselves and apply their newly gained knowledge directly in practice.

After the participants know the basics about the arculee and feel confident controlling it — be it with our fleet manager or with the Robot UI — it is then time to take a step back from the products and learn some tech fundamentals. The follow-up lesson is called Linux basics. This is where we dip our toes into the world of Linux, how it works, and what it can do. The main goal of this module is to take the fear of Linux operating systems away from people who are used to working with Windows and Mac computers — an important step for the last and, for some, most important course: helping an arculee.

Controlling the robot is a crucial part of the trainings

helping an arculee teaches the employees everything they need to know to help an arculee in need. For instance: if a production team member needs to deliver a new robot, but the robot presents issues after the initial assembly, they may need to go deep into the robot software to find out the cause of problems. And that’s one example of when this course comes into play.

The training courses provide the students with enough material and content to understand the system, lose the fear of working with it, and communicate with their team members in a common language.

The impact

After conducting several sessions of the training courses, I’ve had a wide variety of participants. From content team members to embedded software developers and every technical knowledge level in between. I’ve taught people who are very familiar with the products and people from Jungheinrich, to whom the system was entirely new to start with. The broad spectrum of the courses, along with this wide range of participants, makes for very interesting results so far:

  1. New joiners are very happy to have their start in a company boosted forward by such training;
  2. The training courses end up giving the participants points of contact within the company and making them feel more welcome in the team;
  3. It gives people an opportunity to use the robot, to have hands-on experience on how it works, and, thanks to that, to feel more engaged towards the company;
  4. The slides serve as a basis, with links, commands and text that the participants can later use as references to look for information about the products;

Two slides on top of another. The one on the top left shows a list of robot information. The one on the bottom right shows a yellow arculee with the following parts highlighted by red arrows: load recognition, emergency stop, reset button, key switch.
Part of the slides used in the training “helping an arculee”
  1. Employees are provided with a good foundation to learn on their own — it turns out that learning advanced topics without knowledge of the basics is very difficult. Who would have thought?!
  2. And, strangely enough, the greatest impact by far: common language.

The common language

New employees don’t always come from a robotics background. And, even when they do, they are not necessarily used to the company jargon. Fleet manager, brain, drives, lift, controller, and many more are examples of words that mean very different things to different people. These differences make communication very challenging at times. Imagine if second-level customer support can’t understand what the third-level customer support says, even though they speak the same language! That’s a reality that, thanks to the training courses, no one has to endure anymore.

Achieving this common language between teams, departments, and companies has been instrumental in avoiding frustration in crucial communication, accelerating processes and improving cooperation in general. It helps new joiners understand what their team is saying from the beginning and ensures service technicians get fast, efficient phone support before important events.

On the left, the arms of a person in a black sweater can be seen. They are crossing their hands on a white desk. In front of them is a computer. On the screen there is a videocall, where one man with headphones can be seen.
A common language is essential for effective communication

What’s to come

As of now, the training courses are available to anyone who needs them and can be organized upon request. They are then constantly updated to fit the ever-changing software and robot, to include new products and to fit the needs and expectations of the participants – a developer has different needs than a service technician, and the courses must account for that. As long as there is a need, there will be training. And we’ll be teaching people what they need to know about our products. If you plan to join arculus — we are hiring, by the way! — then we will probably meet there someday!

November 11, 2023

Innovation at arculus: Unravelling the Complexity of the arculee’s Wire Harness

In the world of Autonomous Mobile Robots (AMRs), one element plays a critical yet subtle part: the wire harness. Its behind-the-scenes role carefully manages the complex network of cables and wires that drive AMR functionality. To gain insight into the harness tailored specifically for our arculees, we sat down with Anis Cherni, Senior Harness Design Engineer at arculus. He explains the challenges and cross-team collaboration within the harness design process.

Wire Harness: the nervous system of an AMR

Anis Cherni, Senior Harness Design Engineer at arculus, describes the wire harness as "An integrated arrangement of cables, bound together with an insulated material." In the case of AMRs, this arrangement of cables serves as the "nervous system" bringing these robots to life. It allows power delivery and enables communication between electronic components.

Since the arculees need to operate round-the-clock, their nervous system must be exceptionally durable and reliable. The design and manufacturing process of an arculee's wire harness, therefore focuses on ensuring its robustness to defend against diverse environmental factors and mechanical stress points. In addition, ensuring safety and minimising signal interference are crucial aspects of the manufacturing process.

Close-up 3D visualisation of the arculee’s harness design. It includes 3 cables that emerge from the bottom of the screen.
Close-up 3D visualisation of the arculee's harness design

Building a robust wire harness

The arculee's wire harness is designed for durability. It incorporates fundamental components such as wires, terminals, connectors, seals, fasteners and protective sleeves. As Anis emphasises, "Every component within the arculee's harness must be able to endure environmental factors like temperature and humidity variations as well as mechanical stress, like vibrations."

Here is a closer look at each of the components:

Wires

Wires are conductive elements that carry electrical signals and power between different components. Strain relief or mechanical stress protection is vital to prevent wire damage at the connector level, thus maintaining integrity. Additionally, the optimal length and routing of wires are determined by many factors. For example, the assembly and disassembly of the harness.

Terminals

Terminals are a class of electrical connectors that "terminate" by crimping or soldering to wire or cable. They create secure and stable connections. There are a few factors to consider when selecting suitable terminals for our harness, for example:

  • The wire cross-section: The wire cross-section should match the size and capacity of the terminal for safe and effective electrical connections;
  • Conductivity, signal requirements, and minimising voltage drop: These determine the different coatings used (such as gold, tin or nickel), the mechanical fit and even the type of the conductor itself.
Four cable drums in different colours. From left to right: yellow, blue, dark grey, and pink.
Examples of wire used for an arculee's harness

Connectors link multiple wires, cables, or components that allow quick and secure connection and disconnection of electrical power and signals. Several factors must be considered when selecting connectors for our harness, such as the number of pins required and the cost, without compromising quality. The wire cross-section also plays a significant role in determining the appropriate connector. Anis, however, specifies, "We normally try to limit the diversity of connectors we use to simplify manufacturing and reduce costs."

Seals are components that protect against environmental factors such as dust and moisture. They are typically installed at entry and exit points where wires or cables pass through walls, enclosures, or connectors. Proper installation shields the harness from external contaminants.

Fasteners maintain the harness in position, orient its branches and provide fixture points within a robot. Anis mentions, "We develop a fastening strategy for the harness. With this, we can identify where each fastener should be located, which has an impact on the assembly and disassembly, the routing and even the energy dissipation throughout the harness."

Protective sleeves are insulation designed to shield and safeguard wires and cables from mechanical stress areas. For the protective sleeves on our harness, Anis explains:

“During our routing phase, we aim to avoid mechanical stress areas. But if we cannot do that, we design our harnesses with a focus on incorporating vibration-absorbent insulations, strain reliefs, and an optimal selection of components. We also consider the dynamic and static behaviour of our system to prevent any failures from occurring. We further account for temperature and its variations, humidity, corrosion and the flexibility of the harness itself. And with that, different measures can be taken.”

Safety assurance

Incorporating durable components within a harness is fundamental to maintaining the safety of the arculee and its users. To ensure full compliance with industry standards, arculus adheres to specific regulations relating to the manufacturing of harnesses, namely:

  • DIN EN 1175 VDE 0117:2020-10: Safety requirements for designing and manufacturing electrical equipment for industrial trucks
  • ANSI/CAN/UL 3100:2021: Safety standard for automated mobile platforms (AMPs) development in commercial and industrial environments
  • IEC 60757: Code for designation of colours in technical documentation and markings of electrical equipment and products

Minimising signal interference

In addition to well-designed and well-constructed components, the essence of a reliable harness lies in its ability to operate with minimal signal interference. This also entails a commitment to electromagnetic compliance, which is the capability of electrical systems to operate without causing disruptions to other devices or being exposed to interference from external electromagnetic sources.

Detailes look at the harness on an arculee. The highlight of the image is a big red emergency button connected to cables.
A detailed look at the harness on an arculee

"We use filters for signals, shielded communication cables and ferrites to keep up with our tight requirements regarding the safety and sanity of signals," explains Anis. "We also secure wire segregation, keeping high-voltage cables away from sensitive communication lines. And we keep communication lines away from rotating parts that generate an electromagnetic field.", he concludes.

Testing and validating procedures

Testing and validation are crucial in ensuring reliability and durability. There are two parts to these procedures:

  • Testing and validation of the manufactured harness: Here, the manufacturer looks into different checkpoints based on a quality control process. These validate whether the harness is durable and reliable enough to be installed in a robot. Some examples are pin-to-pin wire checks to verify the wiring connections and wire-pulling tests to assess the mechanical integrity and strength of a crimped wire and terminal connection.
  • Testing and validation of the harness installation: The second phase involves installing the harness in the robot as originally intended. During this step, stakeholders within the project, including team members and engineers, provide valuable feedback. Anis explains, "The input we gather may lead to a new revision of the harness, which is then deployed in the robot."

The challenges of wire harness design

Harness design comes with several challenges that engineers must tackle to ensure long-term success. At arculus, two major hurdles are currently at the forefront: scalability and adaptability.

Scalability

Effectively managing scalability hinges on comprehensive manufacturing documentation. Anis highlights this, stating, "arculus improves a lot in harness documentation, which currently allows us to outsource the harness manufacture to different suppliers without having any issues."

Adaptability

Effectively handling changes requires a well-defined change management process that oversees transitions from various parties involved in the assembly line, electronics team, or wire harness manufacturers. Anis underscores the current progress in adaptability while acknowledging, "Right now, we are in a good phase of adaptability when it comes to designing wire harnesses, but there is still room for improvement."

Cross-team collaborations

Collaboration stands at the core of wire harness design as it involves gathering significant insights from various disciplines. As Anis explains, the primary sources of information in this collaborative effort are the electrical and mechanical engineers. Electrical engineers contribute by preparing the schematics, which illustrate the connectivity of wires and signals. At the same time, mechanical engineers are responsible for providing the 3D environment.

To ensure optimal solutions that meet project requirements, frequent communication and feedback between teams is essential to devise the best solutions to specific needs. Occasionally, the firmware team can have an impact on the wire harness through specific requirements that are then incorporated into the design. All of this relies on well-established communication processes within the company or, as Anis puts it, "Communication is always key here."

Meetings are a big part of Anis' daily tasks, ensuring collaboration

Connecting it all

Anis' insights into the meticulous approach to wire harness design and manufacturing, attest to the durability and reliability of our harnesses. This robust "nervous system" is the cornerstone of the arculees' consistent performance as an intralogistics solution. Moreover, our well-structured manufacturing documentation and adept change management processes, help to minimise scalability and adaptability challenges.

The core value of cross-team collaboration further enhances the design process, integrating inputs from various disciplines. With the unwavering expertise and dedication of professionals like Anis and the entire arculus team, the arculee's wire harness continues to push the boundaries of innovation, promising a future where the arculees play an even more pivotal role in the evolving robotics landscape.

November 2, 2023

The Python Advantage: Why It Remains a Top Choice in Tech

Python is one of the most popular programming languages in the world. From recommendation algorithms to self-driving cars and robotics, the use case possibilities are endless. In our quest to explore the dynamic world of Python, we sat down with Darshan, a seasoned software developer at arculus. His insights shed light on the diverse applications the language serves within arculus and the reason behind its adoption. Join us as we delve into the world of programming through the lens of Darshan's experiences and expertise.

A first look into Python

Whether you're a seasoned developer or a passionate tech enthusiast, the odds are that Python has left its mark on your digital journey. The language, first released by Guido van Rossum in 1991, is present in a huge variety of modern applications. In fact, research conducted by code hosting platform GitHub in 2022, found Python to be the 2nd most used language for four years in a row, with four million developers using it in 2022.

But what actually is Python?

Python was born from van Rossum’s desire to write a clean and aesthetically pleasing language. And if you're wondering how a programming language can have these qualities, check out a simple piece of code in both Java and Python:

Python

print("Hello world.")

Vs.

Java

public class HelloWorld {
    public static void main (String[]args) {
      System.out.println.("Hello world");
    }
}

The Python Software Foundation defines it as “an interpreted, interactive, object-oriented programming language”. Let’s break down what each of these characteristics means:

  • Interpreted: developers don't need to compile the code before running it. Instead, the Python interpreter reads and executes the code line by line, making development more flexible.
  • Interactive: developers can interact with the Python interpreter in real time. This interactive mode, often used in the Python shell (REPL - Read-Eval-Print Loop), enables them to enter and execute code snippets one at a time. It's useful for testing small code snippets, experimenting, and learning.
  • Object-oriented: Python follows the principles of object-oriented programming (OOP), where developers arrange code into objects or classes, each encapsulating data and behaviour. OOP promotes modularity, reusability, and a more organised approach to solving complex problems. Python allows the creation and use of objects, making it suitable for developing large and complex applications.

Why is Python so popular?

To better understand the popularity of Python and its crucial role in the arculus tech stack, we asked software engineer Darshan Patel to explain some of the language’s key advantages:

Rapid Prototyping

“Python is a dynamically typed language with ‘batteries included’. This means that it ships with a lot of functionality for performing various tasks, with less overhead compared to statically typed languages”, highlights Darshan. “It also offers the benefits of quickly implementing abstract ideas into something that is ‘almost tangible’, interactive and easily perceivable by everyone. These qualities allow us to quickly iterate over the product, gather feedback and reduce the time to market,” he continues.

Beginner-friendly

Darshan describes Python as having a “very gentle learning curve”. In other words, beginners and experienced programmers alike can easily learn the languages. “Its syntax is also very human friendly and close to natural language. This offers great readability and understandability concerning the existing code”, he explains.

Great community and learning tools

Along with Python’s numerous inbuilt functionalities comes a plethora of online/offline resources available to tackle all sorts of problems. “Resources like libraries, books, courses and tutorials are abundant and can be employed to tackle almost any problem. Furthermore, it has a lively, diverse and inclusive community of people who contribute to teaching, creating and maintaining the aforementioned resources. The community is also happy to help via channels like Forums, Q/A sites and even Discord Servers”, explains Darshan.

Expansive reach

“I would categorise Python as a ‘Jack of all trades’ among existing programming languages because it is ubiquitous within various technical/scientific fields”, defines Darshan. He explains that many disciplines and fields employ Python to solve all kinds of tasks. “This prevalence makes it one of the top choices, since problems from various fields can be tackled using the same language”, he concludes.

Darshan sitting in front of his computer. He is focused, loooking at two monitors.
Darshan focused on his work as a Python developer

Other Python benefits that stand out are:

  • It’s open source: Python’s source code is freely available for anyone to view, use, modify, and distribute.
  • It’s portable: Python code can run on different platforms without significant modifications, ensuring broad application compatibility.
  • It’s extendable: Developers can enhance Python's functionality by adding external libraries and modules.

Python’s libraries

Libraries are “cornerstones of modern software development. They offer pre-built solutions to a variety of problems which can be directly incorporated into the application, rather than writing the solution by hand”, defines Darshan. “Functions like file operations, network communication, Data Structures and Algorithms are commonly used over a wide range of applications. And libraries offer the means to implement such functions with minimal effort. This ultimately reduces the time required to implement the application”, he concludes.

Although most programming languages offer their sets of libraries, Python shines on two fronts here:

  1. Python’s standard (or internal) library comes with an extensive collection of built-in modules and packages that provide a wide range of functionality right out of the box. “On the other hand, languages like C or Rust are shipped with a more conservative amount of internal libraries. So, projects in these languages tend to rely on a high number of external libraries.”
  2. Python’s strong community also ensures that the language boasts one of the most extensive ecosystems of third-party libraries and packages among programming languages. They cover virtually every domain, from web development and data science to machine learning, artificial intelligence, and scientific computing. Some prominent examples include:

  • Numpy: Offers high-performance data structures for performing computations.
  • Matplotlib: Offers means to visualise and analyse data.
  • Qt: Provides GUI (Graphical User Interface) frameworks
  • Networkx: Offers data structures and algorithms for network analysis.
A monitor showing a long snippet of Python code

The not-so-bright side of Python

Despite its many benefits, working with Python doesn’t come without challenges. For Darshan, there are three main disadvantages associated with programming in Python. Here is a closer look:

  1. Limited Performance: "One of the primary challenges of using Python is its limited performance. Being a dynamically typed language, the interpreter has to perform 'checks and balances' while the code is being executed," defines Darshan. These checks and balances lead to overhead during program execution, which can hinder performance.
  2. Concurrency and Multithreading: Darshan also highlights an issue related to modern computer hardware, which often includes multiple processing units known as cores. He explains, "Modern systems have several cores. Python, however, by default, doesn't efficiently use them due to certain technical constraints in how Python code runs." This means that Python programs may only fully benefit from the extra computing power available in multi-core computers if developers specifically design their programs to do so, which can be a complex task.
  3. Type Safety Challenges: Python's dynamic nature means it doesn't provide inherent type safety by default. “As a program becomes larger and more complex, ensuring the consistent use of the right data types across various parts of the application, can become increasingly challenging," points out Darshan. However, modern Integrated Development Environments (IDEs) and code editors include type checkers that promptly alert developers to potential type-related issues. Additionally, external libraries are available that perform static type analysis, proactively checking the codebase for any type misuse.

Python in the real world

Despite its challenges, Python is still one of the most extensively used programming languages across multiple use cases. It serves as a go-to language for data analysis and machine learning, enabling professionals to conduct complex statistical analyses, create data visualisations, and build machine learning models. In web development, Python powers the backend infrastructure, managing data exchange, database interactions, and security. It excels in automation and scripting, allowing users to streamline repetitive tasks and processes efficiently. It also contributes significantly to software development, aiding in build control, bug tracking, and automated testing tasks.

Python as a part of arculus’ tech stack

Python has also been crucial to the arculus tech stack since the company started developing its fleet management software. Darshan explains the reason:

"The programming language selection is mainly done by considering the problem at hand and opting for the best-suited language. For applications that require high performance and efficiency, languages like C, C++, and Rust might be good candidates. Suppose the application focuses on scientific domain problems like Machine Learning, Artificial Intelligence, and Data Science. In that case, Python is a good candidate due to its popularity and the vast amount of existing libraries and applications for said domains."

As the arculus solution portfolio involves a mix of domains, use cases, and scopes, our tech stack is also a complex blend of different languages. “Factors like performance, efficiency, problem domain, time frame, and deployment platform played a vital role in crafting our tech stack,” clarifies Darshan.

So, where exactly do we use Python?

Python and Rust are the two main forces behind our fleet manager. “We use Rust for its safety, efficiency and performance, so that we can coordinate a large number of robots safely and efficiently. At the same time, Python helps us build tools, algorithms and extensions quickly and with ease. It also helps us perform data analysis on our systems for identifying bottlenecks and evaluating performance and behaviour characteristics to serve our customers better”, reveals Darshan.

A close up of a monitor showing a close up of a code written in Python.
A code snippet in Python from the arculus fleet management system

Further languages in the arculus tech stack include C++, Javascript and Typescript. “The software running on the arculees, which allows them to efficiently plan paths within a given environment, is primarily written in C++, whereas Javascript and Typescript are used to build our end-user interfaces, which allow the users to interact with the robots and fleet management system,” he concludes.

TLDR.py

In summary, Python is a versatile and widely embraced programming language. It is exemplified by its rapid prototyping, user-friendly nature, robust community, and diverse applications. However, it comes with inherent limitations, including performance constraints and type safety challenges. Darshan Patel's insights from his experience at arculus, highlight Python's crucial role in the company's tech stack. Despite its challenges, Python remains a powerful tool in the arsenal of developers worldwide, shaping the landscape of software development across various domains.

October 11, 2023

Everything You Need to Know About Rust at arculus (And Beyond)

Even non-techies have probably heard of popular programming languages like Java, C++ or Python. However, a new language has been stirring the programming world in recent years. And it might well be on its way to becoming as mainstream as its counterparts: Rust. In this blog post, software developer Andy Brinkmeyer sheds some light on Rust’s benefits, technicalities, and recent implementation in the arculus tech stack.

A Brief Story of Rust

A programmer gets frustrated with a piece of tech. They get home, sit on their computer and try to solve it. This is the origin and story of several software projects and it’s no different with Rust.

Night scene showing a developer sitting in front of a laptop. Only his torso is visible. He is wearing a dark blue shirt and sitting to the right of the image. His hands are illuminated by the light coming from the laptop.
Several software projects begin with developers trying to solve personal frustrations

In 2006, Graydon Hoare, a Mozilla programmer, was forced to take the stairs to his 21st-floor Vancouver apartment after the elevator software crashed. He knew that such crashes are often caused by software written in C++ or C, which make it easier to introduce memory bugs. And so when Hoare finally got to his apartment, he opened his laptop and began designing a new programming language that would make it possible to write efficient code with improved memory safety. And the story of Rust began.

Seventeen years later, Rust has become one of the most popular languages on the planet. There are 2.8 million Rust developers around the globe, and the programming question-answer website Stack Overflow elected Rust as the most loved language for seven years in a row. Its economic relevance also can’t be questioned. Companies like Microsoft, Amazon, Meta, Discord, and Dropbox have openly talked about how Rust helped improve their system’s performance. And arculus is proud to join the group.

fn main() {
    println!("Hello, world!");
}

Example of "Hello, world!" code in Rust

What makes Rust so popular?

The short answer is that Rust addresses common pain points present in other languages while minimising any downsides. For that, it counts on a few main advantages, namely:

  • memory safety
  • security
  • strong community
  • faster development

Here is a closer look at what each of them means:

Memory Safety

This feature refers to Rust’s ability to pre-emptively avoid memory-related errors. They often lead to crashes, vulnerabilities, and unstable software behaviour. Unlike C and C++, where manual memory management can cause issues like buffer overflows and null pointer dereferences, Rust relies on three key concepts to ensure memory safety:

  1. Ownership: Each value has a single owner, making it explicit who is responsible for managing the underlying memory.
  2. Borrowing: Values can be accessed through references without owning them, which is called borrowing. Strict rules are applied here to ensure memory safety.
  3. Lifetimes: Ensure that references are not used after the data they point to has been deallocated, preventing references to invalid memory.

As arculus developer Andy Brinkmeyer explains, the Rust compiler enforces these rules at compile time. “This prevents most memory-related bugs, which is great”, he explains. The result is more robust and safe software. That's because in other languages, programmers need to manually ensure compliance with memory safety rules.

Security

Due to memory safety issues being responsible for a major portion of reported vulnerabilities in systems, Rust's ability to eliminate these issues significantly increases cyber security.

Strong community

Rust takes pride in having a “community-driven development process where most decisions are made through open discussion and consensus”. The “Rustaceans”, as the active members of the community like to call themselves, constantly create new documentation, resources and even libraries. This makes the experience of Rust fully collaborative and interactive for developers of all levels.

A photo of four developers at the arculus office. They are all talking to each other while working, and appear happy.
The Rust community is also growing inside arculus

Faster development

Rust enables faster programming through its combination of memory-safety and expressive syntax. By catching many common coding errors at compile time, the language reduces debugging time, ultimately accelerating the development cycle.

Rust core features

Andy explains that Rust shares many similarities with C++ since both are "statically typed, compiled languages without a garbage collector". Nonetheless, Rust's popularity comes from some of its unique features. Here is an overview of some of the most prominent ones:

Zero-cost abstractions

As Andy explains, “Abstracting away complicated logic and behaviour is one of the ways we make our software usable. Rust has this guarantee that abstracting away all this complicated logic for data types, does not incur extra cost on your compiled program”. In other words, zero-cost abstractions ensure that using convenient and expressive programming constructs, such as iterators, does not result in slower or less efficient code.

Concurrency and parallelism

Managing tasks simultaneously (concurrency) and utilising multiple processors to speed these tasks up (parallelism) are crucial aspects of modern programming. Still, handling them can be complicated and error-prone. Rust, however, makes both processes easier and more manageable. It does this by ensuring that when multiple tasks work with the same data, they can't inadvertently interfere with each other.

Andy explains that Rust makes working with concurrent and parallel code safer, through its ownership and type system. “Since a value can only have a single owner, it is impossible for two threads to own it at the same time. The type system complements this by marking if types are safe to share between threads, through borrowing and safe to send between threads by transferring ownership”, he elaborates. In other words, Rust prevents many concurrency and parallelism errors at compile time, using the same mechanisms it uses for memory safety.

use std::thread;
fn main() {
let v = vec![1, 2, 3];
let handle = thread::spawn(move || {
println!("Here's a vector: {:?}", v);
});
handle.join().unwrap();
}

Code snippet showcasing how to move ownership into a new thread. Source: Rust book

Pattern matching

Pattern matching is a technique used to compare data structures against predefined templates and execute specific code based on the matched pattern. It simplifies decision-making by allowing developers to handle different conditions in a structured and expressive manner. Patterns can be as simple as matching specific values. Or as complex as matching the structure of data types like enums or structs.

What sets Rust apart in this regard is its commitment to code safety. Its strong type system ensures that pattern matching covers all possible cases and reduces the risk of runtime errors. Rust’s concise and expressive syntax makes code more readable. It also provides features like pattern destructuring, automatic variable referencing, and customisation options.

Cargo

Cargo is Rust’s build system and package manager. What makes it a notable aspect of Rust is its capacity to handle many tasks. Some examples are building code, downloading the libraries on which the code is dependent, and building such libraries – also called dependencies.

“With Cargo, a Rust project centres around a single configuration file, where you define the properties like name, version, and dependencies. Cargo then handles the essential tasks, like setting up the project, compiling code, and linking build artefacts. In practice, using Cargo often boils down to running a single command like 'cargo run,' which simplifies the entire development process."

Andy Brinkmeyer
Two developers sitting next to each other at the arculus offce. They are both looking at their computer screens.
Andy (in the background) working on development tasks at our Munich office

Rust at arculus

The Rust programming language has proven to be a highly versatile tool, with widespread applications across various fields. The most prominent ones include Operating Systems (OS), Kernel programming, embedded systems, and cloud infrastructure. And while its numerous advantages make the number of potential Rust applications grow steadily, there is one field in which it still falls short: robotics.

“In robotics, tasks such as perception, path planning, and localisation involve complex algorithms. These algorithms have evolved over a long time through collaboration between academia and industry, and they are typically implemented in libraries”, clarifies Andy. “Many of these essential libraries are intertwined with C++, creating a dependency ecosystem that reinforces its use. Transitioning from this well-established field, where everything you need is in a single language, to Rust can be a significant step. While Rust is gaining traction in robotics, C++ still holds the number one position in this field for now", he concludes.

So why do we use Rust at arculus?

While using Rust in our robots is challenging right now, the language is the perfect alternative component of the tech stack that makes up our fleet software solution. “We need something with high performance that can manage multiple robots simultaneously. But we also need reliability and safety because the customers depend on us not crashing and not having errors in the code. They rely on us for the system to run indefinitely without problems. And that's why we are slowly implementing Rust”, highlights Andy.

Managing the transition

For Andy, what defines the approach to the transition process at arculus is “learning by doing”:

“Of course, people had time to prepare and study the (Rust) documentation. But we at arculus are really hands-on, in quite a literal sense – hands on the project, hands on the work. And in my opinion, contributing very early in the adapting phase to the codebase was the best way to get people up to speed. This approach combined with regular feedback by experienced Rust developers allowed us to quickly adopt it as a language and get everyone all set.”

Andy Brinkmeyer
Two engineers looking at the same computer screen. Behind them, a few arculees can be seen.
arculus developers like Andy (right) and Dennis (left), take pride in their hands-on approach

Learning resources

With such an engaged and supportive community, Rust is arguably one of the most well-documented programming languages – and that includes learning resources. For Andy, the most useful ones can be found on the official Rust project website. “The official Rust book was for me, the perfect mix between theory and real-world examples. But I also learned a lot through the other resources on the website, like Rust by example”, he concludes.

exit()

To sum up, Rust has emerged as a robust and adaptable programming language that is gaining recognition across various industries. Its origins trace back to addressing the need for safer and more efficient software, a mission it continues to excel at. From memory safety to security, a reliable community, and enhanced development speed, the language offers a compelling package for software developers.

As the arculus team integrates Rust into the tech stack, it leverages the language's exceptional qualities to ensure high performance, reliability, and safety in our software solutions. While the transition is ongoing, we are committed to the "learn by doing" approach, harnessing the wealth of resources the Rust community provides. Rust's journey at arculus reflects its evolution as a language that meets and exceeds modern software development's demands.

September 18, 2023

The arculee’s RCU®: Unveiling the Heart of Our Autonomous Robot

At the core of every robot are electronics components that drive its functionality. In the case of the arculee, the most significant of these elements is the RCU® - one central Robot Control Unit. This blog post delves into the electronic heart of our robot, providing insights from engineer Tobias Schwering. We’ll uncover the RCU®’s integral role in coordinating and enhancing the robot's performance, while discussing the challenges involved in its in-house development and production.

A first look inside the RCU®

The RCU®, short for Robot Control Unit, is the central electronic control module of our Autonomous Mobile Robot (AMR), the arculee. It integrates most of the robot’s functions onto a single self-developed Printed Circuit Board (PCB). arculus’ Senior Electronics Developer, Tobias Schwering, explains that this unit can roughly be divided into five parts:

  • Power distribution system: connects two 48V batteries to power consumers (such as motors and lifts), generates different voltages (e.g., 24V, 12V, 5V) for various functions, and manages the robot’s on and off procedures;
  • Central Computing System: runs the robot’s higher-level software (or "brain") on an embedded Linux module (Nvidia TX2) and provides communication interfaces such as Ethernet and USB ports, as well as a certified WiFi bridge and a 5G mobile modem for connecting to the customer’s network;
  • Three Inverter Modules: self-designed inverters capable of delivering 70A of current, enabling the arculee to perform heavy lifting tasks.

Taking it to heart

In many ways, the RCU® serves as a central hub for the arculee, almost as a “heart”. Firstly, it is the core power distributor within the robot, supplying electricity to all its subsystems. Additionally, it serves as a communication hub, collecting sensor information and processing it within the embedded Linux module. This data is then transmitted to the fleet management software, enabling the generation of precise instructions for the robots.

Keeping it in the family

As with most of the arculee’s inner parts, the RCU® was entirely developed and designed in-house. But Tobias explains that this wasn’t the original idea: “We were planning to have an external company working on it. But we soon realised that the complexity of the system was too high. It was also too entwined with the rest of the robot for such a combination to work properly. So, we brought the design in-house and have never regretted it.”

Tobias working at a desk in front of a window. There are two computers on the desk, one laptop and one monitor. To his left is the RCU®.
Tobias Schwering working on the RCU®

Full control over the RCU®'s design allows the team to directly tailor the arculee's electronics to different customer needs and easily implement new functionalities. The tailored inverter hardware and software design also vastly improved the performance of the robot’s driving system, as it allowed for increased power.

“To develop the RCU® internally, we need a deep understanding of all its subsystems, which enables us to fully optimise all of them to our use cases. And the learning never stops, so each version of the RCU® has substantial improvements over the last one and enables additional use cases.”

Tobias Schwering, Senior Electronics Developer

The RCU® development process

Developing exceptional robots requires continuous refinement. With the RCU®, it’s no different. “Many times we realised that the assumptions we made in advance and that drove the design, didn't fully meet reality. And new requirements appeared during the development process. So, we constantly needed to adapt and adjust the design accordingly.”, explains Tobias.

In other words, with each iteration cycle, the team draws from accumulated knowledge to make necessary adjustments. This involves streamlining the design by removing unused interfaces and systems, creating room for innovative functionalities that enhance the RCU. Along these lines, established performance metrics were also constantly reassessed and refined, ensuring that tasks were clear and well prioritised within the roadmap. Furthermore, to enable retrofitting, the team aims for backwards compatibility of the RCU® where feasible.

Close-up shot of electronic components and circuitry that compose the RCU® . In the center of the image, there is a circuit board with the word "arculus" displayed prominently. Surrounding the circuit board are multiple wires of different colors, including red, green, and blue wires.
The RCU® is constantly going through iterations that involve countless tests and measurements

One of many challenges

The continuous iteration approach allowed the team to overcome a number of obstacles that appeared during the development of the RCU®. For Tobias, “One of the greatest challenges was integrating both power electronics that favour wide and thick copper structures on the PCB and high-density logic systems with high-speed communication – that favour the exact opposite – on the same PCB.”

While having both on the circuit board is possible, it requires special fabrication technology. And that’s what the team tried to avoid, as it would lead to greater complexity, longer lead times, and higher costs. The final solution for the issue involved a mix of creativity, electronics, and craftsmanship, and you can read the full story told by Tobias himself here.

What’s next for the RCU®?

As previously mentioned, robotics developments at arculus are characterised by constant iterations. Therefore, as the RCU® has reached a consistent state, its future developments are constant updates and modernisations. According to Tobias, the next big step planned is updating the Linux module. “As it’s so deeply integrated into our system, we shied away from updating it for a long time. But we have now enhanced most parts of our robot. Thus, we are now at a point where we can really profit from an improved central computing system”, he explains.

Close-up vision of the version 2.2 of our RCU®

The plan is to switch to an enhanced SOC (system on chip) of the latest generation on Nvidia’s Linux modules. And that promises a significant increase in performance and efficiency. “At the same time, we will also integrate a bunch of other smaller improvements”, says Tobias. But readers will have to remain curious about these for now.

The true impact of it all (TL;DR)

In conclusion, the RCU® serves as the beating heart of the arculee, centralising power distribution and orchestrating seamless communication among various subsystems. Its in-house development empowers arculus to tailor this control unit precisely to meet different customer needs, resulting in enhanced robot performance and adaptability.

The continuous iteration approach to development, demonstrates arculus' commitment to innovation. With the RCU® at the core, we continue our journey towards pushing the boundaries of robotics, aiming to integrate the latest generation of Linux modules to further elevate the arculee's capabilities. As the heartbeat of arculus' robotics solutions, the RCU® paves the way for a future of excellence and advancements in autonomous mobile robotics.

“Learning is the key to good engineering. Everyone makes mistakes while designing today’s complex systems, as many challenges are not obvious until someone has faced them. But it is important to grow with these and do it better next time.”

Tobias Schwering, Senior Electronics Developer

August 8, 2023

Rising Above the Fear of Robots in the Age of Automation

Many believe that robots pose a threat to humanity. As they continue infiltrating various aspects of our lives, this raises intriguing questions about our relationship with this technology. In this blog post, we will discuss the origins of the fear of robots, its psychological underpinnings, and how we can overcome the terror of our robotic counterparts.

The fear of automation and robots is not new. Most people had reservations when automation started increasing in the 1950s. They worried that AI and robots would destroy jobs or change society in alarming ways. Little did they know that new industries would emerge due to automated solutions.

The psychology behind the fear

The notion that robots could harbour hostile intentions towards humans exemplifies our relationship's intricate nature. This apprehension, commonly referred to as Robophobia, prompts us to delve into its psychological underpinnings. By examining prevalent beliefs, we can gain insight into the origins of this anxiety. So here are some of the most common fears:

  • Robots could be harmful to our health:

Many individuals have safety concerns regarding autonomous machines, as they perceive them to be dangerous. The greater the robots' capabilities, the more intricate they become. As a result, people may worry that the robots are prone to malfunction, even with multiple safety features.

  • Dependence on automation:

Some show resistance because they believe the world will become overly dependent on robots for different tasks. As a result, humans would lose their proficiency in certain skills and the autonomy to make informed decisions. According to this belief, automation can further create social isolation due to decreased human interaction within the workplace.

Mint coloured futuristic warehouse showing different types of robots working in harmony. In the foreground, there are four AMRS with wheels. A tall robotic-arm-like figure can also be seen on the right.
AI-generated image of a futuristic warehouse
  • Uncertainty is stressful:

The fast-paced progress in robotics is surpassing our society's capacity to fully understand the potential outcomes. As a result, people are becoming worried because they cannot predict the effects of incorporating robots into our cultural, economic, and social spheres.

  • Impact on jobs:

Many individuals argue that they will lose their jobs due to automation. It is true that technological advancements result in job disruption, and their fear is understandable. However, it is essential to note that robots take over repetitive and mundane tasks, allowing workers to redirect their skills to more complex tasks.

Source: McKinsey

Overcoming the fears

Many people believe that automation will lead to job losses, but in reality, it will simply change the nature of work. A report by McKinsey predicts a decline in demand for physical and manual skills by 2030, but an increase in demand for workers with different levels of technological proficiency. As advanced technologies become more prevalent, workers must develop new skills and adapt to new innovations.

It's important to understand that humans are the driving force behind the creation of robots. Teams of designers, engineers, innovators, and technicians work together to bring these machines to life, each bringing their own expertise, skills, and perspectives to the project. Ultimately, robots are simply products of human creativity.

Those who fear robots can also find comfort in the fact that companies building these mechanical machines must also follow mandatory safety standards. Such measures are in place to ensure that robots are safe to use in the diverse applications they were built for. For example, the LiDAR sensors in arculee, our Autonomous Mobile Robot (AMR), can detect a person inside the hazardous zone and stop immediately, thereby preventing accidents and injuries.

In a nutshell

As we navigate the fears and uncertainties created by robots, it is only fair to remember that throughout history, technological advancements ultimately led to job transformations and the emergence of new industries.

Robots are only there to execute tasks for which they were designed and programmed. On the other hand, humans' unique skills and qualities, such as creativity, critical thinking, and adaptability, will always remain invaluable to the evolving workforce. Therefore, it is crucial to evaluate human-robot collaboration benefits rationally. Rather than resisting them, it is in our best interest to perceive them as empowering tools.

July 11, 2023

Faster, Smarter, Better: Intralogistics with Autonomous Mobile Robots

As businesses seek to optimise their operations, Autonomous Mobile Robots (AMRs) have become a reality for intralogistics in the 21st century. We now see robots alongside humans, navigating complex environments and handling materials in factories. In this blog post, our Production Manager Thorsten Mersdorf explains how AMRs improve efficiency in various industries and transform how we look at intralogistics.

Autonomous Mobile Robots (AMRs) are now common in distribution centres, production facilities and warehouses. They are compact, driverless vehicles that transport loads or materials without a fixed, predetermined route. As the name implies, the primary purpose of deploying these robots is to autonomously drive any goods from a given source, to a given sink within the industrial workflow.

Thorsten Mersdorf is leading the AMRs' prototyping, commissioning, production planning and administrating processes, concerning quality management at arculus. He defines them as:

“In fundamental terms, I would describe AMRs as robots that do not require an additional infrastructure for navigation and orientation within the intralogistics system.”

Thorsten Mersdorf, Production Manager
Two men are standing in a robot testing area. The man on the left is wearing a dark blue jacket. He is smiling with glasses on and has a beard. The man to the right of him is also smiling and wearing glasses. Both men are looking at their laptops.  On either side of them there are windows letting natural light into the room, illuminating their faces as they look down at their laptop screens. Behind them, on the floor, is an arculee.
From left to right: Thomas Fuhrmann (Software Engineer) and Thorsten Mersdorf testing one of the arculee Backpacks

What do Autonomous Mobile Robots bring to the table?

AMRs are becoming increasingly popular because of their versatility and quick integration into existing infrastructures. Compared to manual operations, using them in a facility offers many benefits to businesses. Some advantages include reduced labour costs, more efficient work processes, enhanced flexibility, and safe human-robot collaboration.

The two most unique features that contribute to their high performance are:

  • Navigation: AMRs can plan and execute their routes autonomously. The technologies they use, such as high-quality cameras and laser scanners, are responsible for localisation, mapping, and adjustment to unforeseen environmental changes in the facility. If there are obstacles, AMRs reroute and complete their task without causing significant delays. This feature makes the navigation of these robots in the environment more intelligent and efficient.
  • Flexibility: The infrastructure in production facilities and warehouses needs to adapt rapidly too, due to frequent product, process, and market changes. This is where the flexibility of AMRs comes in handy as "Autonomous mobile robots can quickly adapt to the changing environment.", adds Thorsten. This capability to meet changing layouts is one of the reasons why they are so cost-effective.

Autonomous Mobile Robots in the bigger picture

"Industries such as automotive, food, and logistics have already implemented AMRs for different use cases.", says Thorsten. The overall intralogistics system may sound complex, as one fleet incorporates different sizes of robots and infrastructure for logistics and production. "Nonetheless, the applications of AMRs are so diverse that other core industries are either considering adopting them or are actively working on specific automated implementations.", he continues.

Here's a closer look at two of the main use cases for AMRs:

  • Goods-to-Person (G2P) picking:

In a G2P picking system, the AMRs lift up the goods and drive autonomously to the worker at the picking station. It allows efficient collection of items without requiring employees to walk around the workplace. As a result, there is an improvement in picking accuracy and a reduction in workers' fatigue.

  • Pallet handling:

AMRs also transport pallets in warehouses and distribution centres. Throughout the pallet handling process, these robots ensure precise navigation and collision avoidance, thereby reducing the risk of accidents, as well as streamlining the process.

A warehouse setting at a showcase. It represents a VNA use case with Jungheinrich trucks and arculees doing the automatic pick and transport of goods.
arculees operating at an implemented VNA system
  • AutoVNA Use Case as an extension of pallet handling:

One of the innovations in pallet handling is AutoVNA. It uses AMRs for vertical transportation between the warehouse and a picking station and the VNA (a very narrow aisle) for horizontal handling within the warehouse. Together, they form a compelling combination of two transport systems and may help reduce infrastructure needs, such as handover stations in the future.

Insights into the arculee S

From building our first AMR to receiving the statement of conformity from TÜV Süd Product Service GmbH, the arculee has come a long way. The robot's advanced components, such as the high-quality 360° sensors, ensure safety for humans working alongside it. This safety function enables the arculee to detect a person or an object and immediately stop if they are close.

An arculee S standing diagonally in front of the camera in the centre of the image. Behind it is a warehouse shelf with some pallets and boxes.
arculee S all set to navigate in the warehouse

The arculee S can also recognise load carriers of different sizes and efficiently handle a load capacity of up to 1000 kilograms. Furthermore, our robots can conveniently integrate with the host system (for central data processing), thanks to the VDA5050 interface. This protocol standardises the communication between the AMRs and any fleet management software to eliminate compatibility problems.

In addition to the capabilities mentioned above, the latest versions of the arculee S come with an extension option called Backpack. An arculus Backpack is a piece of equipment mounted on the arculee to transport pallets or other load carriers. The extended equipment also has sensors to detect a pallet's availability and correct position in order to enable safe transportation.

AGVs or AMRs?

Automated Guided Vehicles (AGVs) also transport materials but in a different manner. Wires, magnetic strips or sensors typically installed on the floor, guide them through fixed routes to perform repeated tasks. When AGVs encounter obstacles, they usually just stop instead of driving a detour around the obstacle like an AMR could do.

Thorsten uses the Pearl Chain Model (a concept often applied to automobile production systems) as an example to explain the difference. A pearl chain requires a stable flow and sequence of transports. Rerouting is therefore optional. He says, "In a stable system, where a robot has to make multiple rounds on a predefined path, from let's say, A to B, AGVs make more sense.". Therefore, "Using AGVs in the direct assembly environment of an automotive plant can be more advantageous than using the AMRs.", he continues.

Unlike AMRs, Automated Guided Vehicles may have limitations in terms of adaptability and flexibility. But their reliable technology for example, in terms of navigation, is one of the reasons they are used in the automotive industry. Therefore, depending on the specific use case, Thorsten believes both technologies have the right to exist in different industries.

Manoeuvring into the future

With increasing possibilities for logistics automation, use cases for AMRs will likely change in the future. Although it is already evident in logistics processes that have integrated AMRs into their system, automated control is gradually becoming more central. Thorsten views the control centre of a factory as a collection of puzzle pieces. He explains, "Currently, we have a different piece of the puzzle for pre-assembly, production, logistics, or even incoming goods. Eventually all pieces will come together to form one environment or system. So, there will no longer be several use cases or sub-systems, but everything under one umbrella."

Thorsten is convinced that further developments in core components, such as cameras and other sensors, as well as new technologies like machine learning, will positively impact the capabilities of AMRs and thus the demand for AMRs in the coming years. This may enable the AMRs to learn from each other. As a result, we may expect autonomous mobile robots to react more accurately, efficiently, and flexibly in all situations and environments.

June 27, 2023

Predictive Analytics for AMRs: Insights from the AI REGIO Experiment

The integration of artificial intelligence (AI) into manufacturing processes has revolutionised how industries operate. The AI REGIO project, funded under the European Union's H2020 Research and Innovation Programme, has been instrumental in fostering collaboration among Digital Innovation Hubs (DIHs) across Europe. In partnership with arculus, they launched an experiment to optimise robotic systems through predictive analytics and maintenance. This blog post explores the objectives and outcomes of this groundbreaking experience conducted by arculus and AI Regio in cooperation with Forschungszentrum Informatik (FZI).

What is Predictive Analytics?

Predictive analytics uses statistics, Artificial Intelligence (AI), data mining, and modelling techniques to forecast future outcomes. This method analyses current and historical data patterns to determine if similar events are likely to happen in the future. This allows businesses to adjust their strategy, to take advantage and prepare for probable future occurrences, leading to improved operational efficiency and reduced risk.

How does Predictive Analytics work?

Data scientists utilise predictive models to find connections between various components within specific datasets. Following the collection of data, a statistical model is created, trained and adjusted, in order to generate predictions.

Predictive Maintenance

Predictive models have a wide range of applications across numerous and varied fields. Primary use cases include weather forecasting, customer service, voice-to-text translation, and investment portfolio strategies. In the scope of the experiment conducted by AI REGIO with arculus and FZI, the focus was on the so-called predictive maintenance.

In the background, there is a blurred image of a man in a suit pointing his finger at visual representations of the elements that constitute predictive analytics. Namely: Pattern recognition, artificial intelligence, automation, neural networks, algorithm, data mining, and problem solving.

Predictive maintenance uses advanced algorithms to anticipate and prevent equipment malfunctions. By analysing patterns and trends in historical data, predictive maintenance models can forecast when machines are likely to experience a breakdown. This data-driven approach enables timely interventions, optimises maintenance schedules, minimises unplanned downtime, and reduces overall repair costs, by addressing issues before they escalate.

A report by the Deloitte Analytics Institute quantifies the benefits:

“On average, predictive maintenance increases productivity by 25%, reduces breakdowns by 70% and lowers maintenance costs by 25%. It is based on advanced analytics and marks a new way of organising and implementing maintenance on an industrial scale.”

The Experiment

The main goal of the experiment conducted by AI REGIO with arculus, was to leverage predictive maintenance models to make robots more sturdy and efficient. In this context, instead of focusing on optimising control algorithms typically associated with robot navigation, the aim was to improve and optimise processes that could significantly impact arculus' scaling efforts. These include, among others:

  • Optimisation of maintenance intervals;
  • Reduction of regular service intervals (like scanner cleaning) by making service calls on a need basis rather than schedule-basis;
  • Early detection of sensor faults (Lidar, IMU, Camera) to ensure proactive resolution of issues.
Close up of the arculee showing its Lidar sensors.
Proper functioning of the arculee’s Lidar sensors is essential for navigation

The following requirements were defined as success metrics:

  • Accurate and securely repeatable predictions of specific situations;
  • Continuous and automatable data pipeline from customer projects.

The results

The experiment yielded promising results. Firstly, the team successfully connected Internet of Things (IoT) data streams from the robots by utilising a Machine Learning (ML) technique known as automatic schema recognition. This allowed for seamless integration and analysis of the data collected. Furthermore, by creating processing pipelines built on both rule-based and learning-based algorithms, the experiment enabled efficient analysis and prediction of maintenance needs.

The study also established a model repository, featuring pre-trained models designed to facilitate predictive analytics for Autonomous Mobile Robots (AMRs). These models trained using ML techniques on extensive historical data and provided accurate predictions of maintenance requirements. Lastly, the experiment introduced a pipeline element generator to optimise the maintenance process further. This tool allows for the quick creation of new models tailored to specific use cases through a technique called few-shot learning.

Close up of an engineer's hands using a machine to gather electric waves from the arculee's control unit.
Data streams from the robot are a key part of predictive modelling

Next Steps

The next step in the experiment will involve developing a high-performance algorithm based on real-life data. This algorithm will focus on detecting dirt on the laser scanners of the AMRs, enabling proactive notification to the maintenance team for prompt cleaning. With this approach, the trial aims to ensure the AMRs' optimal performance and longevity, as well as minimise any potential operational disruptions they may face.

Meet the Players

AI Regio

The goal of AI REGIO is to enhance collaboration between DIHs across Europe. The plan is to improve regional DIHs' services to small and medium-sized (SMEs) manufacturing businesses. These improvements will be made on three different levels:

  1. Policy Impact

AI REGIO coordinates smart specialisation strategies across European regions and beyond to help scale innovations to global markets. This builds on the Four Motors for Europe movement and the I4MS Community and Innovation Collaboration platform, fostering closer cooperation.

  1. Technological Impact

The AI REGIO uses previous EU-funded projects like L4MS and AI4EU to create Digital Manufacturing Platforms. These platforms are integrated into the services offered by Digital Innovation Hubs. As a result, Digital Manufacturing Platforms receive support for their business and social impact challenges, while also expanding their AI-enabled technological assets.

  1. Business Impact

In AI REGIO, both DIHs and SMEs collaborate on 30 regional application experiments that use AI technology. These experiments focus on helping SMEs adopt AI and include considerations for skill development, privacy, and sovereignty preservation.

FZI

The FZI Research Centre for Information Technology is a non-profit organisation that stands for applied research and technology transfer. Since its foundation in 1985, it has been conducting research in various fields related to computer science. Under the motto "Research is the engine of the future", the institute claims to work towards responsible future shaping.

June 15, 2023

Precision On Wheels: How AMRs Tackle Error-Related Costs

Many companies seek innovative solutions to enhance accuracy, efficiency, and cost-effectiveness in today's dynamic business landscape. Thanks to Autonomous Mobile Robots (AMRs), various industries have been able to automate tasks formerly prone to human error. This blog post will uncover how adopting AMRs can benefit businesses by reducing error-related costs.

In an ideal logistics world, employees would operate order fulfilment processes flawlessly and with no errors. The harsh reality, however, is that mistakes are inevitable and can significantly cost businesses time, money, and in some cases, reputation. Studies suggest that the average error rate in warehouses or distribution centres ranges between 1%-3%, compromising a company's profitability by 13%.

The root cause of error-related costs

Before evaluating how technology can reduce or eliminate inaccuracies, it’s essential to understand why and where such blunders occur. One common human error in logistics happens during manual picking and packing. This is simply the selecting of incorrect or damaged items, mistaking quantities, or damaging packaging. In the best case, the mistake might get detected before the order leaves the facility. The potential loss in this situation could be time or the need to employ extra workforce.

However, if the order gets delivered to the customer without taking measures to rectify the fault, the consequences are more significant. Companies must pay additional expenses, including customer refunds, return process costs, and shipment. They also have to deal with dissatisfied customers, who may lose trust in the company’s credibility because of wrong or damaged products. Ultimately, organisations pay the price for errors instead of reaping profits.

Source: AMWARE

Fortunately, businesses can have more optimised and responsive workflows by incorporating AMRs, like our arculee, in distribution centres, production facilities, and warehouses. They are incredibly versatile, speeding up the picking process and guiding associates through tasks such as picking and packing, inventory management, and the efficient sorting of items. Companies that deploy these robots see minimal faults, increased productivity, and drastically diminished costs.

Fewer mistakes, greater productivity

AMRs can reduce error rates in several ways, optimising the order fulfilment processes to enhance accuracy and efficiency. Some of them are listed below:

  • On a primary level, Autonomous Mobile Robots use their advanced sensors and maps to determine and navigate through efficient pathways and reach the correct picking station. With this capability, employees only have to worry about collecting the right items and confirming the pickups.
  • When AMRs integrate with a Warehouse Management System (WMS), they receive real-time instructions and updates regarding inventory, orders, and task priorities. It heavily reduces the chances of miscommunication that can lead to a potential fault.
  • When robots take over repetitive tasks in warehouses and distribution facilities, workers experience mental and physical relief. It allows them to use their time more effectively by focusing on important tasks, which helps them maintain performance throughout the day. As a result, employees are more dedicated and focused, leading to a reduction in error rates.
Autonomous Mobile Robots transporting load carriers in a warehouse

In conclusion

Many industries are adopting Autonomous Mobile Robots (AMRs) to improve their workflows and reduce errors and costs. This trend is expected to continue, leading to more efficient and successful operations. Automation, including the use of AMRs, is critical to the future of logistics, enabling a more reliable and error-free world.

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D-81541 München

info@arculus.de