Design and Development of an Industrial Warehouse Pick & Place Robot
– 20% reduction in overall project cost
– Scalable solution that can fit any warehouse size
Background
The growing demand for automation in industrial environments has led to the widespread adoption of robotics in warehouse operations. With a particular focus on efficiency and accuracy, robotic systems can drastically improve the functionality and output of warehouse processes. At Srushty, in one of our key milestone projects, collaborated with a robotics company in Germany to design a pick-and-place robot tailored for such applications, aiming to enhance the speed and reliability of warehouse operations.
Objective
The primary goal of this project was twofold:
Develop a Robust Drive System: To engineer a drive system capable of moving the robot horizontally and vertically, ensuring precise and efficient item handling.
Enhance Product Quality: To improve the robot’s capabilities and performance, making it a competitive asset in the fast-paced warehouse environment.
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Problem
The key challenge rested in integrating complex mechanical and electrical systems to create a seamless, robust robot that could operate under the demanding conditions of a warehouse. The robot needed to handle various item weights and sizes, navigate efficiently between locations, and perform picking and placing tasks with high reliability. All these activities required careful consideration of the robot’s mechanical strength, control systems, and operational efficiency.
Our Work
Mechanical Design:
Drive Mechanisms: Developed specialized mechanisms for both horizontal and vertical movement, allowing the robot to navigate warehouse racks efficiently.
Stress and Force Calculations: Conducted thorough analysis of payload capacities, drive forces, torque requirements, and speed to ensure durability and functionality. This included calculations for shear stress, bending stress, bending moments, and twisting moments.
Component Selection: We selected standard mechanical components that met the defined requirements, optimizing for cost and performance
Electrical Engineering:
Driver Package Development: Built and tested peripheral driver packages, ensuring compatibility and efficiency.
Actuator Testing: Utilized NVIDIA Jetson technology for frugal testing of actuators, which allowed for accurate simulations of predefined movements.
SCARA Robot Arm Integration: Integrated a commercial off-the-shelf SCARA robot arm for effective picking and placing operations.
Operational Design:
Track Movement: Implemented X and Z direction movement capabilities on tracks, enabling the robot to move across warehouse racks with precision.
Pick and Place Mechanism: Designed a reliable platform for the robot arm, facilitating smooth pick and place operations from storage racks to bins
Highlights
Belt-Driven Gear Mechanism: Employed a belt-driven gear mechanism for handling high-load applications, ensuring the robustness required for warehouse operations.
Dual Movement Capability: Engineered the system for both vertical and horizontal movements using the belt-driven mechanism, enhancing the range and flexibility of robot operations.
Impact
The successful development and implementation of this pick-and-place robot have significantly impacted warehouse operations by:
Increasing Efficiency: Reduced time in item picking and placing, enhancing throughput.
Improving Accuracy: Minimized errors in item handling, leading to fewer damages and losses.
Project Impact:
Cost Reduction: Achieved 20% cost reduction on the overall project budget for developing this robot end-to-end.
Scalability: Provided a scalable solution that can be adapted to different warehouse sizes and operations.
The industrial warehouse pick-and-place robot represents a leap forward in robotic automation for warehouse environments. Through meticulous design and strategic integration of mechanical and electrical components, this robot is one of the strategic engineering solutions delivered by our team.
