4am automates high-bay warehouse feed at automotive OEM

4am Robotics is currently implementing a project at an automotive OEM using our AFi-M (autonomous forklift). The previous, manual process is quickly explained: An existing high-bay warehouse with several conveyor stacks must be supplied with material. In addition, empties must be removed from the system. Up to now, five manual forklifts were used for this in three-shift operation.

Euro pallets, on which KLT containers are positioned, are transferred to the conveyor stacks. After the containers have been removed from the pallet, empty pallets are stacked in the station and made available for collection as bundles by the conveyor system. These are picked up and placed in a defined empties location for final removal. In addition to the conveyor stitches for full pallet infeed and empties removal, there is also a conveyor stitch where NIO (defective) goods must be picked up and placed in a special clearing location.

The described process has so far been carried out completely manually and will in future be carried out by 7 automated stackers (AFi-M) in a future-proof and error-free manner. Of course, there are activities to be performed in the process that seem trivial to a human being and his sensory organs, but challenge a machine. We want to specifically focus on these challenges, as the corresponding solution approaches convinced our customer to trustfully hand over the project into the hands of 4am Robotics.

Therefore, the pickup height of the pallet must be recorded individually for each pickup. For increased safety of the overall environment, a pallet breakage is checked before the pickup to avoid shifting / overturning of the stack. Another additional safety feature is an automatic, instantaneous weight detection system built into the forks. This helps the AFi-M to comply with cycle time requirements. The correct pick-up of the pallet is finally checked.