Christian Wurll is involved in several development projects, including automated case picking and eCommerce.
The automated case pick development project is a ongoing venture continuously looking at new package types
and improved ways to sequence and palletize product.
The variety of different product and packaging types (e.g. corrugated cardboard boxes, shrink wrapped items, open trays or boxes)
in a distribution center have little in common, which makes automatic depalletizing and order picking difficult.
However, as most package types have at least a flat bottom, KUKA has designed a universal gripping system incorporating a roll-up principle.
This enables you to handle layers of products where most other conventional technologies fail.
In this process, two servo driven rubber rollers are pushing against the pallet layer from opposite sides.
The packages are thereby lifted up and rolled onto two symmetrical carrier plates. The gripper control software automatically adjusts
the contact pressure and height position of the rubber rollers to suit the package weight and dimensions.
The roll-up principle supports a multiple layer pick cycle; thus, the overall picking performance can be significantly increased.
The maximum layer number is limited by either the maximum payload weight or the maximum payload height.
MXRP is an efficient robot-based case palletizing system that utilizes the latest in flexible gripper technology.
The Mixed Row Palletizing gripper technology enlarges the application spectrum for mixed palletizing. The gripper works in
tandem with a load station that groups cases in the proper sequence and then elevates the product, allowing the gripper forks
to gently lift the packages from the bottom. The design allows handling various package types, including open top cases.
The MXRP gripper has a number of innovative components, one of which being the Flex Strap system; this makes exact positioning possible,
as there is no friction between the product and fork. Another innovative part of the MXRP gripper is the forks, which can be adjusted
both horizontally and vertically as well as left and right. This holds a unique advantage for mixed palletizing in the fact that a
traditional true mixed pallet has uneven layers and therefore, it is difficult to palletize more than one or two cases at a time
with any stability. However, with the versatility provided by the independently working forks, up to 4 – 6 cases can be moved at a
time and accurately stacked on a pallet, regardless of the profile of the layer previously assembled. Due to the ability to move
complete rows at a time instead of individual cases, the palletizing cell can achieve up to 1400 cases per hour, depending on the
order lines and product portfolio. This increased throughput is achieved with only one robot as compared to two robots required
in conventional palletizing cells achieving 1000 cases per hour, a direct savings in equipment costs and floor space.
Grenzebach.MXRP is a comprehensive Windows application for processing picking orders. Grenzebach.MXRP has its own user friendly
human machine interface, which allows the operator to monitor, control and troubleshoot the system and gives an overview about
current orders assigned to the MXRP robot cell.
The Grenzebach.MXRP application communicates with all necessary distributed systems within MXRP robot cell. For example it
controls the automatic programming of the robots for Case Palletizing. With a direct communication connection, operators can
check robot states directly in the user interface. In the same way the application maps processing and communication states of
sensors and PLC-interfaces. All interfaces are logged in a readable fashion which simplifies the system diagnostics.
Grenzebach.MXRP creates performance and error log files for a daily, weekly, monthly and yearly process evaluation.
All control applications provide the required user interfaces to resolve possible error situations. Below are different user
dialogs are displayed from the different HMI applications. If an application recognizes an error situation, then it will notify
the WCS accordingly including an unique error message.
In case of a pick error, the Grenzebach.MXRP will display feasible resolutions, which the operator can select to continue or abort the
active mission as shown below. In the same fashion every robot cell HMI will indicate an error situation by flashing certain buttons
in red color. Following the red color will guide the operator to the appropriate dialog.
The Automated Mixed Pallet Pick is managed by the WCS, per the defined sequence of truckloads and the sequence of pallets within
a truckload. The WCS will manage the outbound conveyors of each zone, making sure that the right sequence kept on the pallets
conveyor and on the RDP conveyors. If manual palletizing is required after the automated palletizing station, the WCS will stop
the pallet in front of the worker, informing him what to pick and the QTY (PBV or on a screen). Once the worker confirms palletizing,
the pallet will be released. Shortages will be interfaces to SAP: Route, Pallet ID, SKU, QTY Pallet ID label for ASN will be generated by the WCS.
The Grenzebach Group is offering two applications to convert the original order lines into customer order pallets. With the first
application “CubeIQ” pallet type specific layer templates can be created.
Therefore, two main functionalities are provided: “QubeIQ LoadEdit” and “QubeIQ Optimizer”. Users can easily design product-specific
layer patterns and rules like stack different products on each other.
Die auf komplexe Fertigungslösungen, Anlagenbau und Automatisierung spezialisierte Grenzebach-Gruppe stellte deshalb jetzt das neu
entwickelte Intralogistik-System „G-Com“ vor. Diese Lösung besteht aus einem mobilen Lagersystem, einem Fahrerlosen Transportsystem (FTS)
mit robusten, intelligenten Transportfahrzeugen (FTF) sowie ergonomischen und variabel konfigurierbaren Pick-Stationen, an denen die
Kommissionierung der Sendungen erfolgt. G-Com ist speziell ausgerichtet auf die Anforderungen im dynamisch wachsenden E-Commerce-Markt.
Als flexibles, automatisiertes Lager- und Kommissioniersystem, das praktisch ohne Standardisierung auskommt, ist es nach Angaben des
Herstellers prädestiniert für verschiedenste Einsatzmöglichkeiten und Branchen, etwa bei Fulfillment-Dienstleistern, im
Pharma-Großhandel oder in einem Ersatzteil- und Nachschublager.
Die Grundidee des Systems bilden mobile Regale, die von kleinen Robotern, den „Carrys“, unterfahren, angehoben und vollautomatisch
zur Pick-Station transportiert werden. Die Regale sind in ihrer Aufteilung völlig variabel und können somit Artikel unterschiedlichster
Abmessungen und Gewichte sowie hängende Konfektion lagern. Damit sind sie auch bei sehr heterogenen und sich oft verändernden Sortimenten flexibel einsetzbar.
Über den Warenhausmanager des Kunden wird die chaotische Lagerung einzelner Regale organisiert. Der Grenzebach-Flottenmanager übernimmt
diese und steuert die Flotte der Grenzebach-Carrys. Die Carrys können durchgängig fahren, da sie sich induktiv aufladen.
Dadurch muss der Kunde nur so viele Carrys kaufen, wie er auch operativ einsetzen will – zusätzliche Fahrzeuge,
die stundenlang in Ladestationen verweilen, entfallen.