Brose has been using an automated guided vehicle system (AGV) from ek robotics in Hallstadt since 2021. It is already the second project of its kind: an AGV from ek robotics with nine Smart Move automated guided vehicles (AGVs) is in operation at the British Brose plant in Coventry. Gerald Röhner, Head of Production Logistics at the Brose Group: "The positive experiences from the Coventry project in England spoke in favor of ek robotics. However, the main deciding factor for the project in Hallstadt was that ek robotics was able to present an overall concept that was also convincing from a commercial point of view. The choice for Hallstadt also fell on the transport robot from the

Smart Move, there are currently a total of twelve AGVs in the L14 high-lift version, three of which can be used for special applications as small load carriers.

The aim is to automate work processes that were previously carried out manually. Gerald Röhner: "A special feature there is that not only the transportation of large load carriers (GLT), but also that of small load carriers (KLT) can be automated. Due to the limited routes, mixed transportation of manual traffic and AGVs would not be possible. That's why we wanted to develop a system that could also load and unload small load carriers fully automatically."

Complex overall system with many interfaces

With 700 spaces for GLT alone, the initial situation in Hallstadt is challenging. For small load carriers, there are around 1,400 spaces with almost 90 different variants for pallets and containers. The transport robots' route is 800 meters long and very complex with several narrow passages and intersections with high traffic volumes. The numerous stations are intended to link the automated warehouse, an automated conveyor system and dispatch with production at Brose.

The collaboration with Brose has been extremely constructive right from the start. "Brose provided all the necessary data in advance and the collaboration was excellent. It was a challenging project for both sides in terms of process technology," recalls Nico Dietrich, Sales Manager at ek robotics. Brose used the simulation service offered by ek robotics to determine the key data and, above all, the required number of transport robots for the future AGV in advance.

Brose wants a high degree of flexibility in the layout of the AGV so that the system can be adapted independently even after commissioning. Training of the people involved by ek robotics - another service provided by the robotics experts - ensures this.

The implementation begins with the creation of the route for GLT transportation. At Brose, they are mostly used to transport large-volume products and finished parts such as door modules for motor vehicles. The course is expanded step by step. The results are continuously monitored in order to identify and eliminate any obstacles at an early stage. A few weeks after the start of the installation, the system for the automated transportation of the GLT goes into operation. The specialists from ek robotics and Brose then begin to integrate the KLT logistics into the AGV.

Automation also for KLT transport

KLTs are playing an increasingly important role in supplying the production lines at Brose - standardized plastic boxes in which small and consumable parts are transported from the material warehouse to the last meter of production. A transport solution for up to 20 such KLTs including automatic pick-up and transfer is required. Brose has already developed the prototype of a mobile flow rack for this purpose: a gantry trolley that is suitable for mounting on a transport robot. In collaboration with ek robotics, the original design of the KLT gantry trolley is being optimized for assembly on a Smart Move.

The implementation of the KLT transport runs in three phases. Firstly, tests will start at the ek robotics plant for technology, IT and safety. In the second phase, an accompanied mode follows in Hallstadt to teach the AGV, the interaction of the stations and the camera technology used to control the KLT transfer. In the third phase, the people responsible for the AGV are trained at Brose, including acceptance of the system - especially with regard to safety in live operation.

The result is unique in this form, explains Gerald Röhner: "The handling of small load carriers in particular is ergonomically critical and cost-intensive. However, small load carriers are becoming increasingly important in production, especially because the number of variants in assembly is increasing and batch sizes are getting smaller and smaller. The fact that we have succeeded in automating this area is really a major step forward."

AGVs as a check-up for the overall system

By analyzing all work processes, the company gains valuable insights for the overall system, says Gerald Röhner: "We were able to identify and eliminate disruptive factors and weak points in the entire system, for example in the conveyor system, shipping and transport. We were able to use the data to further optimize our assembly processes. We have standardized the interfaces and processes between assembly and logistics and, of course, improved the intralogistics route network by leaps and bounds."

Even after the successful implementation of the AGV with twelve Smart Move, the cooperation with Brose continues. Currently with a maintenance contract and a 24/7 hotline that is available around the clock for questions and service. It cannot be ruled out that Brose will also consider the innovative solutions from ek robotics at its other locations. In any case, Brose is extremely satisfied with the AGV for Hallstadt. "We are proud of the result and also of our involvement in this outstanding project," confirms Gerald Röhner.

The article appeared in materialfluss 8-9/22.