Unique project in Germany

Martin Schrüfer,

Drone instead of transporter: successful world premiere in plant logistics

In a unique nationwide project, Frankfurt University of Applied Sciences (Frankfurt UAS), Merck and drone manufacturer Wingcopter are currently designing and testing the use of delivery drones in cross-site plant logistics. A special drone is used to fly pigment samples from the Merck plant in Gernsheim to the laboratory at the science and technology company's headquarters in Darmstadt, around 25 km away, where they have to be analyzed to ensure quality in the ongoing production process. Up to now, transportation has been carried out by a van that travels the route between the plants twice a week. The official drone maiden flight took place successfully on February 5, 2020.

© Frankfurt UAS

The core task of the "ProGeDa - sample transportation between Gernsheim and Darmstadt" project is to evaluate this transportation case across all plants and to develop a long-term business model from this. Aspects such as time savings, sustainability, costs and flexibility will be taken into account. The Research Lab for Urban Transport (ReLUT) at Frankfurt UAS is evaluating it under the leadership of Director Prof. Dr. Kai-Oliver Schocke, Professor of Logistics and Production Management at the Faculty of Business and Law, with the support of Keimer Aviation. ReLUT focuses on the development of economic and ecological solutions for delivery and freight services. The startup Wingcopter developed the special drone, plans and carries out the flight operations and coordinates all aviation law issues. Merck controls the overall process and provides the goods to be transported. The current project is being funded by the Federal Ministry of Transport and Digital Infrastructure with a total of 107,000 euros as part of the Modernity Fund ("mFUND") funding guidelines. Wingcopter and Frankfurt UAS are receiving this funding. Wingcopter was selected for the project because its drones have all the characteristics required for air freight transportation between two or more plants: They can take off and land vertically in the smallest of spaces, but can also cover longer distances much more efficiently, quickly and quietly than conventional multicopters thanks to their swivel-rotor mechanism.

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The project focuses on determining an optimal route between the two locations, taking into account a wide range of framework conditions (aviation law, environmental protection, suitable take-off and landing areas, ground processes, costs, etc.). The three cooperation partners assume that transportation by drone will not only prove to be faster and more sustainable, but also more cost-effective and flexible. "With this project, we will demonstrate the sustainability of drone flights for commercial purposes in public spaces in all three dimensions of sustainability - ecological, economic and social. We assume that it will be widely scalable and transferable to other sectors," says Schocke.

Tom Plümmer, CEO of Wingcopter, adds: "We have already proven many times that our delivery drones offer a significant advantage over conventional, ground-based means of transportation or even manned aircraft in a wide variety of applications, especially life-saving ones in remote regions of various developing countries. Thanks to this unique project, we can show that this also applies to commercial deliveries in metropolitan areas of industrialized nations."

Stefan Nowak, the responsible project manager at Wingcopter, emphasizes: "We are not aware of any other project in the world in which goods are delivered by drone over such a distance and out of sight in a metropolitan region - across power lines and train lines, freeways and federal highways as well as production infrastructure. With today's flight, the project marks a milestone in the history of unmanned aviation and intermodal logistics." Furthermore, the project is a role model for similar projects worldwide in terms of the coordination and approval procedures under aviation law.

Jens Klatyk, head of the Merck site in Gernsheim, also sees advantages of the project: "Not all relevant analytical parameters are implemented in the analytical laboratory in Gernsheim. Special tests are carried out in the laboratory at the Darmstadt site. Instead of transporting the samples by car, drone transport offers the possibility of faster and congestion-free transportation." Time savings of between one hour and one day are possible. In addition, empty runs and emissions can be avoided.

Based on the data obtained during the delivery flights and the survey of the overall processes, the cooperation partners will present a final report at the end of the project phase in March 2020. The report will outline the conditions under which the use of drones in plant logistics can be operated in an economically and ecologically sustainable manner. This will result in recommendations, possible further use cases and operating concepts.

Before the start of the project, the startup Wingcopter was already in the StartUp program of the House of Logistics and Mobility (HOLM) at Frankfurt Airport and part of the Accelerator program at Merck's Innovation Center. During this time, the team worked intensively in the innovation center's makerspace and used the rapid prototyping lab to further develop its vertical take-off and landing drone. The idea for the ProGeDa project emerged from the constant exchange with internal employees, which was supported and accompanied by the Merck Accelerator and the Innovation Center as it progressed. The project is an example of the variety of collaborations that start-ups can initiate as part of Merck's Accelerator program.

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