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.
In addition to learning about the target product and coordinating with other departments, a lot more goes into the production cycle of the arculees. Let’s find out how to build a robot with mastery.
How to Build an AMR
The AMR production involves several key stages:
1. Pre Assemble
The actual process begins in Dresden, home to the arculus warehouse. Here, the team carefully thinks through the material selection beforehand. For example, we rely on corrosion-protected steel for the arculee M's structural components, ensuring durability and strength.
Leveraging an innovative modular approach, the arculee M comprises separate modules for different components, with dedicated teams putting each one together. This strategy allows for the pre-assembly of modules independently from the main construction, providing remarkable flexibility. It facilitates scaling and allows for outsourcing before the final assembly.
Thorsten further explains, “First of all there are the key modules. For example, the Electronics Module focuses mainly on the Robot Control Unit (RCU), also known as the robot's heart. Others include the Active and Passive Lift Module, the Drive Module, and the Chassis. Lastly we have the Auxillary Modules that cover all functional parts, such as cameras, key switches, access points to the robot, and all the UI features and environmental detection sensors.”
2. Assemble it All
The main assembly follows the fishbone principle, using cause-and-effect diagrams (resembling a fishbone structure) to create an optimal concept. Once that’s in place, the team installs each pre-assembled module into the robot. Of course, it is not simple, and the team considers several factors for aligning and securing the mechanical parts of the AMR. These include ensuring the tolerance of each part, optimising the fitting process, getting the specifications right, and maintaining strict quality control throughout the supply chain.
3. Integrate the Robot
Configuring and calibrating different components and software is also crucial for the robot's proper functionality. At this stage, the team integrates the motors and sensors into the robot via the RCU and the S7 Safety process. Effective implementation of safety features in the AMR is critical for on-site equipment and personnel protection. Other tasks covered during the integration stage include:
- Software flashing: Depending on the needs, it may include updating, resetting or rebooting the robot software for smooth operation.
- Scanner, camera, and sensor adjustments: Calibrating the cameras, scanners, and sensors is crucial to ensure that AMRs collect accurate data about their surroundings for efficient object detection and navigation.
- Robot lift system and drive configuration: Fine-tuning these systems ensures the AMRs can move and position themselves seamlessly at the customer facility.
4. Test
Testing involves checking the system, application, and performance to ensure safety and functionality. The team uses the four-eyes principle, meaning at least two people evaluate each process to guarantee accuracy. For this, we have quality checks throughout the production process. We also conduct other evaluations, such as the system test on the bench and the robot’s endurance test. The idea is to confirm that the AMR is functional according to the quality requirements and follows the safety standards.
The entire process of assembling, integrating, and testing a robot takes around 10 hours. However, the estimate doesn’t include the time spent defining the concepts and processes, or arranging the modules.
5. Have a Cool Team
A group of people who are passionate about what they do is one measure of the success of any project. The production journey of an AMR, like that of arculee M is no different. As Thorsten explains:
“Teamwork is also extremely important in production. If we don’t align the team towards a goal, we won’t be able to harness the skills of each individual in the best possible way. As a result, we’ll fail to awaken the required ‘winning spirit.’ But if we create the right environment, teamwork can develop, and the members will trust each other and ultimately enjoy taking on challenges and solving problems.”
Thorsten takes pride in the squad - a group of highly talented, driven, and creative individuals:
Jonas Jaeger is the Team Lead for Assembly and Integration and manages teams, resources, and the production area in general.
Federica Granato and Anika Lorenz, the Production Engineers, are responsible for quality assurance for the arculees and the warehouse management.
Josef Bauer and Marcel Trouillaud are the Mechatronic Experts. They cover integration and end-of-line processes.
Tamas Szipli is the Production Expert. He handles key resource assembly, tooling, and planning.
Diego Hidalgo, Integration Expert in Mobile Robotics, tackles tasks related to software and the robot UI.
Konstantin Bikard and Stefan Klein, the Production Technicians, take care of the assembly and equipment setup and adjustments for safe, high-quality robots.
Fazli Senel is the Robotics Service Engineer. He tests and maintains the AMRs for efficient robot operation.
“If you take a closer look at production and its environment,” continues Thorsten, “teamwork is one of the main factors contributing to smooth processes and good product quality.”
6. Have the Right Tools to Hand
The other crucial resource for efficiently building agile robots is the tools. When it comes to specific equipment, Thorsten mentions various items for different stages of AMR production:
- For organisation: To effectively structure and manage tasks and processes, we use different software such as operations1, Assemblio, and Jira.
- For assembling: Depending on the task, the team may use various tools. Usually, these include assembly tables, cranes, and torque screwdrivers.
- For calibration and testing: We have equipment and calibration benches for post-assembly configuration and software packages to optimise the performance of the AMRs. We also use the self-developed Robot UI for several End-of-Line (EoL) processes to ensure the proper functionality of the AMRs.
7. Have an Awesome AMR - the arculee M
Once the arculee M is built and functional, it is ready to transport materials in warehouses, supporting the automation of the intralogistics industry. The most impressive specs of the arculee M include:
- Flexibility with transporting of pallets
- More room for higher load capacity, i.e. 1,300 kg
- Effective obstacle avoidance system
- VDA 5050 compatibility
If you want to adopt the arculee M as a solution in your facility, please visit Jungheinrich for more information.
In short, arculus with its continuous commitment to innovation, assembles and integrates the arculee M as an efficient Autonomous Mobile Robot for intralogistics. To sustain this success, it's essential to remain agile and responsive to the ever-changing technological advancements and dynamic demands of the intralogistics industry. By continually adapting, evolving, and optimising our processes, Thorsten’s team turns these challenges into opportunities, advancing our production standards and contributing to the ongoing advancements in the field.
