The useful guide provides engineers with valuable information about how to introduce automation into manufacturing practices successfully, so they can realise the full potential of robotics and achieve increased productivity, reduced downtime, improved worker safety, and lower operating costs.

The guide is described as an essential read for engineers looking to adopt automation and robotics into their operations. The guide is full of practical hints and tips, and simple steps that engineers can take to make introducing automation easier. For example, the guide details valuable information, best-practice actions and checklists in sections such as project preparation, project implementation, project operation and project maintenance.

The guide also outlines common mistakes and pitfalls in adopting automation. Engineers can learn from real-life examples about what to avoid and what can happen when automation adoption doesn’t go to plan. For example, this could include poor product selection, a lack of joined-up thinking between engineering and IT staff or failure to devote enough time for deployment.

Critical information on building the right foundation and establishing targetable objectives and the importance of creating contingencies is highlighted in the guide. Engineers can also gain valuable insight on a range of planning methods available, and the need to perform comprehensive testing and validation.

To ensure lasting success, the guide explains that it is vital to consider two areas which are often overlooked: project operation and project maintenance. The guide highlights that spending time to analyse and refine operations can prove valuable, ensuring optimal efficiency and equipment longevity.

Engineers can learn operation management tips and potential maintenance errors. For example, the guide explains the importance of monitoring performance, setting and tracking key performance indicators (KPIs) as well as giving suggestions for KPIs, such as total cycle time, system availability, or production schedule attainment.

Additionally, the guide emphasizes the importance and power of partnerships for maximum effect, and the need to find a trusted parts supplier to help keep robotic systems in perfect working order. Global parts suppliers such as EU Automation can provide expert guidance and advice around areas such as predictive maintenance, helping end users to alleviate any potential problems that could cause downtime before they occur.

“Adopting automation requires a structured and systematic approach to achieve the best chance of success,” says Darren Halford, managing director at EU Automation. “We work closely with our customers to help support them on their automation journey, and this handy guide offers a framework of practical advice, enabling engineers to deliver all the advantages of automation, whatever their application.”

The need for automated processes is growing, with the market for industrial robots predicted to reach USD 31.3 billion in 2028, according to Fortune Business Insights. Manufacturers become increasingly aware of the potential business and production benefits of implementing robots. Nevertheless, industrial robots are not without drawbacks. Here are some of their most common limitations and some suggestions of what manufacturers can do to overcome them.

Affordability

Generally, industrial robots require a large upfront investment, including additional installation and configuration costs. Manufacturers also need to consider future maintenance costs and the need for extra components.

Similarly, robotics is a constantly evolving industry, with upgraded machines always appearing on the market. Investing in new robots regularly might be a struggle for some companies, particularly smaller ones that could go bankrupt in the attempt to keep up with industrial trends.

However, industrial robots can help manufacturers cut costs in different areas. They can reduce production costs and increase profits by optimising work. With a clear investment strategy and financial plan, robots are most likely to bring a fast return on investment.

Another smart alternative is to invest in reconditioned robots. Typically, used robots cost half as much as new ones, while maintaining their efficiency and operability.

Safety

Industrial robots have always been considered somehow dangerous on the factory floor. And for good reason – they are big, hulky pieces of equipment that can move at very fast speeds. Older machines even lack the sensory capabilities to detect nearby humans, making them prone to dangerous collisions and accidents. For this reason, many manufacturers add cages or dividers to separate robots from their human co-workers.

More recently, with the introduction of collaborative robots, which are smaller, lighter and designed specifically for work with humans, safety has become one of the main priorities in industrial automation. More regulatory practices have been put in place for both hulky industrial robots and cobots.

While there is still way to go to achieve absolute safety in the factory, there is no doubt that progress is ongoing. New technologies like light curtains, laser scanners and presence-sensing devices are widely accepted as a method of increasing humans’ safety.

A good practice for manufacturers is also to conduct an individual risk assessment of their production line and train workers on how to react in a potential accident.

Harder to train

Industrial robots require expert programming and training to perform tasks, so companies need to hire experienced engineers and programmers to oversee the installation of robots. On top of that, even experienced personnel might need retraining when new software is developed or new robots appear on the market. If a robot is not programmed properly, it can lead to malfunction and harm those around it.

However, in recent years a new method of training robots has been implemented – the no-code or low-code programming. It allows employees with less coding experience to configure a robot using visual modelling and drag-and-drop user interfaces. Due to the easy-to-use format of no-code and low-code platforms, robots can also be reprogrammed for different jobs by just adjusting their arm. While companies would once require multiple robots, now a simple adjustment can be made by a non-technical person, saving companies time, space and money.

The trend of low and no-coding platforms is rising, with 84 per cent of enterprises in the US, UK, Canada and Australia implementing low-code development platforms to lessen coding needs.

Industrial robots have been proven to simplify human work, bring a fast ROI for manufacturers and streamline production. Nevertheless, they are not without limitations. They are harder to train than humans, require high investment and maintenance costs and pose safety challenges. While these are valid concerns for manufacturers, they can be address with careful planning and new technologies to overcome them. At EU Automation, we believe industrial robots are indispensable assets for smart factories and we always keep up with the latest news in their developments.

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Could low-coding and no-coding robotics be the key to solving the sectors skill shortage? Here Neil Bellinger, head of EMEA at automation parts supplier EU Automation, discusses the use of low-code and no-code robotics in manufacturing and the advantages of this technology.

The transformation to programming as we know it through the introduction of low-code and no-code platforms makes the implementation of robotics in automation more accessible. Low-code and no-code robotics simplifies complex programming using visual modelling and drag-and-drop user interfaces. Therefore, little to no programming knowledge is required.

Low-code automation platforms usually comprise built-in visual modules which are quick and easy to use. However, these platforms do require some coding knowledge when implementing complex or specific interactions. Although those with no coding experience can use low-code automation, there is still a need for coding at points.

No-code automation platforms, on the other hand, require no coding knowledge. Users instead automate processes through graphical user interfaces rather than traditional programming. The interface works via drag-and-drop boxes that imitate user interactions with a computer. These platforms completely remove the need for technical knowledge and are designed to accelerate the automation process.

Advantages of application

Low-code and no-code robotics applies to various processes in the manufacturing industry, from material handling to welding. For example, due to the easy-to-use format of no-code platforms, robots can be reprogrammed easily for different jobs via the adjustment of their arm. While companies would once require multiple robots, now a simple adjustment can be made by a non-technical person, saving companies time, space and money.

One of the ways this technology benefits the manufacturing industry is by addressing the STEM skills shortage in the industry. The use of low-code and no-code platforms in manufacturing increases the flexibility and autonomy of automation. The high level of feature richness and integrations allow for the automation of any process to meet the companies demands, providing more opportunities for employees and potential employees with no technical background.

The application of no-code robots and cobots can benefit manufacturing companies through a higher return on investments (ROI), decreased operating costs, and improved reliability and precision. However, this kind of investment may prove expensive for smaller manufacturers due to the initial cost of implementing these robots.

The trend of low and no-coding platforms is rising, with 84 per cent of enterprises in the US, UK, Canada and Australia implementing low-code development platforms to lessen coding needs. This interest in low and no-code is likely to rise in the future. At EU Automation, we always look for the latest trends in automation. From HMIs and displays to motors and encoders, we provide for all needs, helping manufacturers progress and democratise the field of robotics.

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In sectors such as consumer electronics, textile and food and drink, a seasonal peak in demand is a well-established fact. This creates a much welcome revenue stream for manufacturers, but it can also mean that factories could struggle to meet customers’ expectations.

Temporary workers are often hired to support companies, but this is not always a convenient strategy. On top of their salaries, manufacturers will have to account for the time and cost of training and the extra equipment that seasonal staff will need to perform their duties.

On the other hand, industrial automation can help lighten the workload at peak times, while optimising processes all year round. So, which operations can be automated to help manufacturers manage the workflow more efficiently?

Inbound logistics

Handling incoming goods or raw materials efficiently is key at times of high demand.  Automation can help move, inspect and store items safely and hygienically, while preventing operator fatigue and injuries.

Automating even one element of logistics, such as unboxing inbound products, can add tremendous value. For example, the IBOD box opening system by TM Robotics eliminates the necessity to open boxes manually, saving time while preventing incidents due to workers working under pressure with scissors or knives.

Pick and place

Collaborative robots – or cobots – are incredibly quick and easy to set up and can be used in a huge variety of applications to automate repetitive tasks, such as picking and placing items. On top of working safely alongside humans, cobots can be easily moved around the factory floor, meaning the same machine could be used at an assembly station in the morning, and moved to packaging in the afternoon.

Cobots also come at an attractive price compared to bulkier robotics solutions. For example, Universal Robotics’ UR5, one of the most popular cobots on the market, is usually sold for 35k USD and can be set up by operators with no programming experience.

Packaging

Packaging can be very time-consuming and automating even one step of it – such as boxing, or labelling – can save time and money. This will give personnel the chance to focus on more complex tasks that require problem-solving skills, increasing capacity across the production chain.

For example, the Sewtec case closer can close up to 30 cases per minute with different closure types. The machine is also optimised to handle delicate products gently and guarantee smooth transition between one case and the other. This can save your employees valuable time while preventing injuries from lifting heavy items.

Quality inspection

There’s no greater waste of time than doing the same job twice. Re-working costs due to production defects extend lead times and are a massive source of lost revenue. Plus, defective products erode customers’ trust and damage your reputation.

Manual inspection is not a reliable quality assurance method, especially for complex products like electronic components. Machine vision systems can help automate quality inspection and can be quick and easy to set up. For example, the S70 by Inspekto is an off-the-shelf machine vision system that can be set up in a very short time without the help of a third-party expert.

Smart digital solutions that automate common and repetitive tasks can be a lifesaver for manufacturers during a seasonal rush. However, investing in automation will be a long-lasting investment that will maximise productivity all year round.

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From the first cobot in 1996, which was designed for basic pick and place applications and which communicated with the operator using motion resistance, cobots have come a long way towards supporting humans’ work in a safe way. They are now able to detect objects and people in their environment using vision sensors and slow down or stop functioning in case of an unintended contact.

Modern cobots also possess the ability to take corrective actions and minimise risks, but sophisticated models take a further step in imitating human-like problem solving. Touch sensing technologies are quickly evolving to increase both the applicability and safety of cobots, especially in demanding applications that require handling delicate materials safely and precisely, such as healthcare.

Preventing collision

There are currently several tactile sensors used in cobots, including piezoelectric, piezoresistive, capacitive, and elastoresistive types. Piezoelectric technologies are used for gathering data from the cobot’s joints and transmitting it to the controller. On the other hand, capacitive sensors can act as proximity sensors, allowing the cobot to slow down when it detects the presence of an obstacle.

Most detection sensors are placed outside of the cobot, such as area sensors, that enable the machine to slow down or stop when human workers are close to it. Although collisions might still happen, these technologies ensure that the impact is minimised. To make navigation more reliable, tactile sensors may be embedded at the end of the cobot arm, just like in a human arm, and equipped with artificial intelligence to avoid collision at all times and allow the cobot to move more efficiently.

Precise object handling

Tactile sensors can also be used to identify the features of objects and recognise defects and changes. For example, early research from the USC Viterbi School of Engineering used embedded tactile sensors with conductive fluid to simulate human touch, resulting in a robot differentiating between the texture of wool and that of cotton.

Modern touch sensing systems use tactile sensors to gather different information about an object, such as shape, size, texture and transmit an electrical signal to the controller. They then measure the real characteristics of the objects producing accurate information. This is helpful for defect detection at a deeper level, by being able to spot issues with the texture of objects.

These sensors are also valuable for precise object placement, when loading parts into a fixture for machine tending. The sensing technology can find the exact part location and correct changes in the position or size of the raw stock material by measuring the insertion force.

With a more effective sense of touch, cobots could be used in applications where they interact with more fragile or deformable objects. One possibility could be using tactile technology in surgical cobots to enhance precision and accuracy. For this to be successful, multiple tactile sensors would have to be integrated using AI and machine learning.

Advancements in tactile sensors for cobots allow humans and machines to perform increasingly complex tasks in a collaborative environment to achieve more productivity and accuracy. An agile work environment that plays on the strengths of automation is key to a successful business. At EU Automation we encourage the development of automation technologies and help manufacturers reduce downtime by sourcing components safely and timely.

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In recent years, manufacturing companies have invested heavily in industrial automation. McKinsey, a consultancy firm, estimates that the market for industrial robots has been expanding at approximately 19 per cent since 2012 and is now worth 16.2 billion dollars. As robots become more ubiquitous, their vulnerability to cyberattacks becomes a more pressing concern.

The threat is real

Every year, hackers and IT professionals meet at the Black Hat cyber security conference. This year, Federico Maggi, a researcher at Trend Micro, and Marcello Pogliani, an information security researcher at Politecnico di Milano, presented a report entitled “rogue automation” in which they presented new vulnerabilities in the software of industrial robots to cyberattacks.

The research reveals previously unknown ways of how an advanced hacker can perform targeted attacks on robots. What makes this possible is a lack of layered user authorizations in software. Once a perpetrator has gained access to the peripheral layers of the software, the entire operating system of the robot could potentially be hacked.

The two researchers believe that existing security mechanisms are not sufficient to protect robots because they have not been embedded in the programming language of the operating system.

Affected are industrial automation robots in sectors as diverse as automotive, avionics, military, pharmaceuticals, food and beverage. The authors of the report argue that if such robots were hacked, the consequences could range from downtime of factory lines to physical or environmental harm.

Spotting loopholes

One of the challenges in mitigating these newly discovered software vulnerabilities is integrating different software from new machines with legacy technology. The programming language of industrial robots is often vendor specific. On the factory floor, machines from different vendors, bought over a long timeframe are required to interact seamlessly with each other. However, some legacy equipment contains code that was written before the time of code checkers, which nowadays spot loopholes automatically.

What can be done to make industrial robots more secure? To reduce vulnerabilities, process engineers should segment networks and isolate machines that process data from outside. Moreover, networks and their endpoints should be protected. Changes to the software should be reviewed regularly and documented scrupulously.

Tackling the problem of cybercrime in industrial automation requires the close collaboration of installation engineers, maintenance technicians, IT service providers and parts suppliers. Industry 4.0 can only be made a reality if manufacturers are able to trust that their industrial automation equipment is safe from cyberattacks.

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Small and medium-sized enterprises (SMEs) are the economic backbone of some of the most industrialised countries in the world. In Germany, for example, they generate about 37 per cent of total corporate turnover.

SMEs represent a very attractive market for robot manufacturers, who are adapting their offer to add flexible, user-friendly and cost-effective solutions to their portfolios. These can be a real asset for smaller businesses, but to choose the best one for their needs, manufacturers should ask themselves the right questions.

Why do we need it?

Manufacturers might fall victim to the pressure to digitalise without a specific strategy in mind, but assessing the plant’s real needs is key to investing in the right tools.

Ask yourself what kind of challenges your company is experiencing, and whether or not they can be tackled by industrial robotics. Are you struggling to fill positions for repetitive manual tasks? Are dangerous operations impacting workers’ safety? Would you like to add night and weekend shifts without increasing labour costs?

These issues can be successfully tackled with robotics. Indeed, if a task doesn’t require thinking on the spot, creativity, or human dexterity, it can probably be automated.

Can we afford it?

SMEs are usually characterised by small production runs, but thanks to the latest innovations in collaborative robotics, manufacturers no longer need huge volumes to build a solid business case for investing in robotics.

According to robot supplier RobotWorx, an industrial robot typically cost between £50,000 and £80,000. However, small and flexible alternatives, which are ideal for low-volume production, are available at a fraction of that price.

For example, US-based Automata recently launched on the market Eva, a robot priced at just £8,000 and programmable in under 30 minutes. Eva is ideal to automate a variety of repetitive tasks, such as pick and place, machine tending, sorting and dispensing.

Another low-cost option for pick and place applications is Delta Robot, developed by igus. The cost for a Delta Robot ranges from £10,000 to £15,000, including integration costs, and its typical ROI period is estimated at just six months.

These small, flexible robotic arms are accessible to most businesses and add substantial value by freeing up human workers from tedious, repetitive tasks and allowing them to focus on jobs that require decision making and problem solving.

Do we have the technical skills?

A typical challenge for SMEs is the perceived need to hire a specialist to programme the robot and fix technical issues. In reality, most robot manufacturers have user-friendly options that don’t require any specific technical background to be set up and programmed.

Eva, for example, is the protagonist of several YouTube unboxing videos where users explain how they assembled the robot and trained it to perform several tasks, in as little as 20 minutes. Other robots, like Delta, come pre-assembled and are ready to be programmed in a few easy steps.

In addition, all robot manufacturers and integrators offer training to their customers. For example, the Universal Robots Academy is a free platform that teaches core programming skills to all UR cobots users, large or small.

Replacing parts to fix or customise your robot can also be relatively easy. With the help of a reliable automation supplier like EU Automation, manufacturers can get the parts they need in as little as 24 hours.

Too many businesses assume that robots are not for them and miss out on the benefits of automation. By embracing robots, SMEs can futureproof their operations and gain a substantial competitive advantage.

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Machine breakdown can incur serious costs for manufacturers. It can prevent production, delay orders and raise labour costs. To reduce the risk of downtime, manufacturers are introducing more intelligent technology to the factory floor. Automated equipment, for example can increase productivity, accuracy and flexibility. However, manufacturers need to consider how they maintain new technology, for the benefits to be long term.

Collaborative robots (cobots) can work alongside humans to complete tasks. Traditionally, industrial robots were large, caged machines that humans could not interact with as they were heavy, unaware of their surroundings and posed a safety risk.

Unlike their heavier counterparts, cobots are easy to program and can work alongside people. They also come equipped with safety features that mean they stop or slow down when a human is nearby, which reduces the risk of a collision or safety threat.

Businesses ranging from small to medium enterprises (SMEs) to large industrial companies are purchasing cobots to improve their workflows.

Cobots and maintenance

Most cobots are not designed with maintenance capabilities in mind. However, in-built functions mean that they can help technicians to reduce the risk of unplanned downtime.

Collaborative robots are built to complete complex tasks normally performed by humans to increase accuracy and reduce fatigue. This means that technicians can use cobots to complete intricate maintenance tasks in a hazardous environment, for example, when a machine excessively overheats.

Small and medium manufacturing companies can see the benefits from a cobot’s versatility. Collaborative robots can be programmed and reprogrammed quickly, so they can be used for a variety of functions, with a quick and easy change in between.

Manufacturers can take advantage of this flexibility to place a collaborative robot at the most suitable point in the assembly line, to ensure it has the greatest impact on the business. SMEs should look to collaborative robots particularly for smaller tasks, as this means it can be added to current infrastructure rather than replacing the entire system.

Robots go mobile

British online supermarket Ocado is using collaborative robots to improve its maintenance processes. The company collaborated with manufacturers to build the ARMAR-6 prototype, an autonomous, humanoid robot that can help engineers reduce time spent on maintenance in the factory. The ARMAR-6 uses a three-camera system to detect and recognise humans and objects, speech recognition to understand commands and hands with grippers to pick up objects.

“The ambition is that the robot will be able to decide what the technician’s intentions are and chip-in as appropriate at the right point in time,” explains Graham Deacon, robotics research team leader at Ocado Technology. This will assist technicians in maintaining the automated warehouses the company relies on to complete orders.”

The future

Robots like the ARMAR-6 are changing how we interact with machinery. In the future, this relationship has the potential to grow even more. Artificial intelligence and machine learning allows robots to learn as they work and make their own decisions.

As cobots experience more, they will be able to recognise and anticipate issues, alerting humans of any potential breakdowns. Employees or robots could then carry out maintenance on the machine before it impacts production.

In future, it may be possible to program a cobot to independently complete maintenance tasks across the factory floor. As they are lightweight and cage-free, manufacturers could mount a cobot onto an automated guided vehicle (AGV), so it can freely move around the factory without disrupting human workers.

More technology in the factory could just mean more machines that are at risk of breakdown. However, the growing capabilities of automated technologies such as collaborative robots can improve maintenance processes to ultimately optimise productivity. One day, a robot may be able to fix itself.

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From robotic conductors to robot vacuum cleaners, there is a vast choice of automated systems available for different purposes. Because there are so many options, it can be difficult for companies to choose which model to invest in. Here, we share EU Automation’s top three considerations when choosing a robot.

The first priority when deciding which robot to purchase should be to narrow down by application, as this determines the type of robot needed. If you’re looking to automate a pick and place activity, a SCARA robot might be most suitable. If your application requires the robot to work closely alongside human staff, a collaborative robot will most likely be for you. Different applications will require different numbers of axes of motion, payloads, speed and reach. It is important to check these features to make sure the robot can perform the task required at your facility.

Once you’ve specified the action you’d like the robot to perform, you can consider the size of the work area to make sure it will suit your production line.

Manufacturers must also take into account the accuracy and repeatability of the robot, as this will impact its performance on the production line. It is a common mistake to buy an accurate robot without considering how well it repeats the accurate motion.

Operating costs

Robots are unlikely to break down soon after purchase, but as time goes on the machines can wear and break. In order to keep costs down, manufacturers should consider maintenance before purchasing a new robot.

It’s useful to know if the robot manufacturer or systems integrator that you’re purchasing from offers a preventative maintenance contract, whether this is 24/7 and what it includes. Knowing this in advance will minimise the risk of a breakdown and being hit with unexpected costs down the line.

Running costs will also depend on the expected use of a robot and power usage. Looking at the reliability and life span of the robot may help to guide you towards the best value for your application.

Social implication

Introducing a new robot is sure to impact your staff. This is particularly noticeable when introducing collaborative robots, which work directly alongside humans. Companies must ensure that staff are comfortable with the purchase and receive sufficient training.

You should ensure your company has the capacity to provide any training needed so that staff understand robot programming and operation and can follow safety standards like crush zones and access areas. The programming ability of your staff must be up to the challenge of a new robot, otherwise it will be extremely difficult to operate it correctly.

The best robots are well designed, safe and user-friendly. By thinking carefully, manufacturers can combine a human workforce with a robot to best achieve business goals.

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Here, Jonathan Wilkins, marketing director of obsolete industrial parts supplier, EU Automation, discusses how automated guided vehicles have advanced from simple materials handlers to intelligent autonomous robots.

Automated guided vehicles are mobile robots that follow markers or signals during navigation. The first AGV was introduced in the 1950s by Barrett Electronics, and performed a simple towing action, with its position guided by a wire in the floor. Since the 1950s, the market has rapidly increased and AGVs are used across numerous industry sectors.

Why AGVs?

Automated guided vehicles are predominantly used for materials handling purposes. This can include a range of tasks from on time delivery of parts to the production line, to round the clock transit. If the vehicle is equipped with a clamping mechanism, positioning fixtures and tool attachments, it can perform a range of functions.

Depending on the application and requirements, AGVs can function in isolation or in fleets. This makes the use of AGVs scalable according to need, so a plant manager can make a specific decision on the number of vehicles in a facility.

AGVs can be equipped with sensors for traceability, so that the plant manager can monitor the position of each individual vehicle and therefore track the movement of materials around a facility. Pick-up, transit and delivery of items can be time stamped as part of this process to further improve tracking. This information can be integrated into the company’s enterprise resource planning (ERP) or materials resource planning (MRP) systems.

Depending on the application, there are different types of vehicle navigation methods. A plant manager can opt for a very simple system, similar to the earliest AGVs, or can choose more advanced navigation methods.

Navigate

The earliest AGVs were guided around the factory by a wired method. To navigate in this way, a wire is embedded into a slot in the floor, and transmits a radio signal, which can be detected by a sensor on the AGV. The AGV is then guided around the facility following the wire. Though this navigation technique is still used today, there are a variety of other methods for plant managers to choose from.

Some AGVs use guide tape that is either magnetic or coloured to navigate. Sensors on the AGVs detect the tape and this is used to guide the vehicle. Guide tape is also used in laser target navigation, where reflective tape is mounted on walls, poles or machines and the AGV calculates distance using a laser transmitter and receiver. This has an advantage over the wired method, because it is easier to change the route of the vehicle as the process of relocating the tape is more straightforward.

In inertial navigation, reference points are embedded into the factory floor at x,y coordinates. The AGV uses information from a sensor, a gyroscope and a wheel encoder to determine location. Changes can be made to the pathway by simply altering the reference points, making this method more flexible. However, some change to factory infrastructure is still required, and the vehicle cannot make independent route planning decisions.

The next step from inertial navigation is open path navigation – this means the vehicle can move independently from one place to another, moving from a guided vehicle to a self-driving vehicle.

From guided to self-driving

Traditional AGVs perform defined, pre-programmed movements around a facility. This means there is some difficulty changing the vehicle’s route once specific infrastructure is in place. Recently, more flexible and intelligent vehicles have been introduced, which are able to make decisions in situations that they haven’t encountered before.

This new breed of vehicle can overcome one of the key problems for AGVS – encountering something unexpected. In a changing environment, a self-driving vehicle may be a better fit. This type of vehicle operates independently from a driver or a fixed pre-programmed input directly controlling the steering, acceleration or braking. Laser-based perception and navigation algorithms can be used to dynamically navigate around a factory.

An on-board programmable logic controller (PLC) can be integrated to reduce errors and make decisions. By connecting to the central control system, the vehicle can analyse the reliability and efficiency of its routes and adapt them accordingly. The vehicle can use machine learning to be more efficient across new situations.

Self-driving vehicles can use an on-board computer and increased numbers of sensors to complete more complex tasks, including decision making. Independent and intelligent navigation methods can even mean the plant manager does not need to modify factory environment or infrastructure. One such navigation technique is natural feature guidance, where the vehicle can record and store images and calculate its position in relation to existing features.

An example of an autonomous AGV is Clearpath Robotics’ OTTO, a self-driving vehicle that can move up to 3,300 pounds at 4.5 mph. OTTO can adapt to take the best route, avoiding collisions as it moves.

The vehicles can also use vision-based guidance systems, using cameras to act as eyes. An additional benefit of this is that plant managers gain a 3D virtual view into the environment the equipment is operating in. This means if the AGV does come across anything unplanned or unusual, the operator can easily find the explanation and correct it.

As more factories are upgraded and new facilities are built, advancing AGVs will prove to be a core component of the smart factory. With improving sensor technology and increasing autonomy, AGVs are becoming smarter and more dynamic, moving from guided vehicles following a set path, to autonomous independent decision makers – much like Konrad’s animals will as they grow.

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