An Austrian manufacturer of industrial plugs and sockets is reaping the benefits of an automated mobile robot (AMR) solution from KNAPP.
PC Electric manufactures more than 24 million industrial plugs and sockets each year, using advanced injection-moulding machinery that the company develops itself. Headquartered in St Martin im Innkreis, Austria, PC Electric exports over 80% of its products worldwide. Despite significant growth in order volumes, the company was still transporting empty containers from the packing area back to the production hall manually via a narrow route, over 100 metres long. The firm sought an automation solution that would be space-effective yet flexible for the future, thereby ruling out a conveyor system. “We wanted to simplify empty container transport, make work more ergonomic and free up resources,” explains Tobias Aichinger, Head of PLC Programming and Robotics at PC Electric.
Stable stacks
The company opted for an Open Shuttle solution from KNAPP, comprising two AMRs and two stations, one for collecting the empty containers from the dispatch area and one for depositing them in the production hall. The AMRs feature a special load-handling device to stabilise the stacks of containers, which can be up to 1.6 metres tall.
Precise docking
The solution is managed by KNAPP’s KiSoft FCS (Fleet Control System) software, with no connection required to the host system. The intelligent KiSoft FCS makes precise docking of the Open Shuttles possible. In addition, the AMRs feature a module to communicate with the rapid-action door at the end of the corridor, so that it opens automatically when a robot approaches.
Safe operation
The Open Shuttles move around the facility independently and safely thanks to 3D obstacle detection and special sensors. The intelligent technology enables them to navigate the narrow corridor, avoiding both forklift traffic and pedestrians. The battery life for an Open Shuttle is more than 6 hours and when its charge drops to 10% – or if it has no orders to fulfil – the AMR returns to the charging station autonomously.
Scalable solution
As no construction work is required to install an Open Shuttle system, projects can be implemented quickly. The technology provides a dynamic solution, with the KiSoft FCS enabling reconfiguration of the layout and processes with just a few clicks of a mouse. Additional shuttles can be added to a fleet within hours and can begin operation immediately, making the solution scalable as a business grows.
Successful partnership
The development departments of KNAPP and PC Electric worked closely during the automation project. Together, they developed the special load-handling device to stabilise the container stacks. “KNAPP definitely delivers on service, customer care and support,” says Tobias Aichinger, “and we are very satisfied.”
Wide range of AMRs
As well as handling trays and tray stacks, KNAPP’s range of Open Shuttles includes models to transport containers, cartons and pallets. There is also a version with a width-adjustable clamp, suitable for handling loads in the electronics sector, such as circuit board magazines and reels. The AMRs help manufacturers to mitigate labour shortages and adapt quickly to change. The Open Shuttles are also ideal for dealing with seasonal peaks, as more robots can simply be added – they can even be rented instead of purchased.
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