Ground-breaking outdoor application – automated forklift truck performs material handling

At Ostendorf Kunststoffe GmbH, automated forklift trucks now support the logistics chain and perform tedious, repetitive and unattractive tasks in outdoor areas. At the beginning they were faced with the challenge of achieving a safe and efficient autonomous operation outdoors. The successful implementation of this using a sophisticated sensor concept was possible thanks to a collaboration between three proven specialists in industrial automation: the forklift truck expert Linde Materialhandling, the experienced automater Götting , and the market leader in industrial sensor technologies SICK.

The trend towards the automation of industrial trucks in outdoor areas continues to pick up steam. This is due not only to the increased requirements on productivity and safety, but also to the serious shortage of skilled workers. As one of the pioneers in the sector, Götting KG already anticipated this over two decades ago and established an innovative business unit, the “FOX” department, to expand its product offerings with automation solutions for series-produced utility vehicles. But the demand only grew to the current high level as a result of the present serious worsening of the personnel situation in the producing industries explains Felix Weiß, Head of Industrial Trucks, Götting: “We now have an absolutely dramatic personnel shortage in companies. There is a lack of forklift truck drivers, in particular in warehouse logistics, because their area of work is generally not very demanding and highly repetitive. Furthermore, shift work is seen as not very attractive. Automating the forklift trucks provides one solution to the problem, including in outdoor areas, it delivers a quick benefit, and can ultimately help the company to survive the intense competition.”

Sustainable thanks to automation

To remain sustainable, Ostendorf Kunststoffe GmbH therefore also relies on automated guided vehicle systems. The company has been one of the leading manufacturers of wastewater pipe systems in Germany for over 50 years and aims to further expand its market position through continuous investment in the automation of its material flow.

At its factory site in Vechta, automated forklift trucks have recently started taking care of the handling and transport of materials. To this end, a Linde E20 LI-Ion forklift truck was retrofitted with sensors from SICK to enable it to independently perform load handling and transport without user interaction based on a definable priority list. The AGV operates without a master controller and independently assigns itself transport tasks via sensor messages to the conveying equipment. Boxed goods on standard EU pallets are first provided via roller and chain conveyors in front of the production halls. The automated forklift trucks independently collect the loaded pallets from there. They transport the material in the outdoor area to the temporary storage area along pre-defined routes, and transfer the material to the conveying equipment for put away. In the current development stage, the AGV connects three sources with one sink with no human intervention. The expansion of the system by one source and two sinks is currently being implemented.

Weather-independent with suitable sensor concept

The weather conditions outdoors play almost no role anymore for the forklift truck. Neither precipitation, flying pollen and leaves, or strong sunlight hamper the safety and functionality of the automated vehicle.

This weather independence is made possible by a sensor concept that takes into consideration all application parameters after a comprehensive analysis. This includes not only the vehicle type and goods to be transported, but also the particular location of use and the routes. Götting developed the concept at Ostendorf together with Linde and SICK and then implemented the optimal sensor solution. “The solutions of the leading safety supplier satisfy all current basic requirements on industrial automation with a clearly defined product liability for outdoor applications.”

 

Reliable outdoor sensor technology for protecting people and materials

“To protect people, the company Götting relies on the outdoorScan3 safety laser scanner and the Flexi Soft safety controller, and for collision avoidance and machine protection the TiM laser scanner,” explains Daniel Salas, Key Account Manager Mobile Platforms, SICK.

To pick up the pallet and then put it down again with positional accuracy, the automated forklift truck “takes its bearings” with marks on the conveyor system using the oS3 safety laser scanner integrated at floor level. The load transfer area is designated a hazardous area. In the loaded state, the forklift truck always moves in reverse so the load cannot slip or even be thrown off in case of emergency braking. The outdoorScan3 safety laser scanner ensures the reliable protection of people thanks to intelligent algorithms and the safeHDDM® scanning technology. For contour navigation, it scans the environment in a radius of 275° and provides distance values to the system via Ethernet. The data is filtered at system level and used for fine positioning, e.g. when parking, when picking up and putting down the load, and at the vehicle charging station.

The TiM 2D LiDAR sensors on the roof of the vehicle are responsible for lateral protection. Using protective fields parallel to the vehicle, undesired access to the vehicle, collisions with objects projecting laterally into the travel path, and lateral collisions are avoided. The sensors provide a high level of performance for the field evaluation and measurement data output and have a scanning range of 25 meters and working range up to 270°. The vehicles and their controller and sensors are designed to absolutely avoid any collisions with the surroundings.

This high level of collision protection can hardly be achieved from today's perspective with a manned forklift truck. Materials and equipment are protected and their service life extended. The automated forklift truck also enjoys a high acceptance among the employees. The personnel feel completely safe, even when the automated forklift trucks are moving about in the same environment as manual forklift trucks, trucks, and employees.

Intelligent accessory ensures improved sensor performance

To further expand the functional safety and availability even in poor conditions, SICK offers intelligent accessories like the airWiper, which removes water droplets from the optics cover of the outdoorScan3 using compressed air. Intelligent software components also have a positive impact on the performance. The AGV Dynamic Weather Assist safety system with weather-independent dynamic protective field switching allows continuous operation even in variable weather conditions with rain or snowfall. The forklift trucks then reduce their speed and drive with more robust protective fields that prevent unplanned vehicle stops and thus weather-related interruptions to the material flow.

Felix Weiß is delighted by the solution: “Our application shows that not only indoor but now also outdoor logistics can be automated end-to-end. The integrated safety mechanisms are reliable and ensure a smooth, risk-free automated material flow. Furthermore, the system enables us to flexibly respond to peak times and quickly adjust our capacities. In this way we are shaping the “autonomous” future in close cooperation with SICK.

 

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