There are more warehouses using robotics technology now than ever. The market for warehouse robotics was worth $2.28 Billion in 2016. It is expected to grow at 11.8% CAGR between 2017 and 2022 to reach $6 Billion by 2022. The U.S. market is leading the charge.

 

Warehouse robots come in a variety of functionality. This allows warehouses to choose the right robotics solution for their specific processes. Warehouse managers should be able to identify the best technologies for their warehouse. 

 

This article provides an overview of the market for warehouse robots and the various types available. It also explains how they work, use cases, and other essential information about warehouse logistics automation needed to be able to make informed technology investments.

 

Different types of warehouse robots

 

Warehouse robotics includes many robots that can move inventory around the warehouse. Let's look at some of the different kinds of warehouse robots.

 

• Automated Storage and Retrieval Systems - These systems automate the inventory process by retrieving and returning goods to storage AS/RS solutions can include shuttles that move between racks or cranes that retrieve goods between aisles.

 

• G2P technology -- Akin to AS/RS technology, G2P technology is a goods-to-person picking robot that delivers items to picking stations. Operators are stationed at these stations to fill orders as the items are delivered.

 

• Automated Guided Vehicles (AGVs) AGVs are self-driving forklifts that transport inventory in a warehouse from one place to another. AGVs use tracks or magnetic strips to travel along planned routes. Sometimes, they are paired with sensors and camera vision technology to avoid obstacles.

 

• Automated Guided Carts -- AGCs and AGVs can be grouped together. AGCs can carry lighter loads.

 

• AMRs -- AMRs are autonomous mobile robots that independently transport inventory and materials through a warehouse. AMRs are different from AGCs or AGVs, which follow fixed routes and are guided by magnetic strips or tracks, but AMRs use maps and sensors to find more flexible ways and interpret the environment. One type of autonomous mobile robot is the autonomous inventory robot. Autonomous inventory robots can count inventory items and equipment that has been RFID-tagged. They do this at predetermined intervals or times. Collaborative mobile robots and autonomous mobile robots amrs are also included in this category. They assist humans by guiding them through tasks.

 

• Articulated Robotic Arms -- Multiple-joint robotic limbs and articulated automated arms lift and move items in the warehouse. They are used in receiving functions such as moving things from pallets onto racks, shipping, picking, and placing.

 

• Unmanned Aerial Vehicles -- When equipped with RFID technology, unmanned aerial vehicles (UAVs) provide real-time inventory visibility in warehouses.

 

Payload capacity is another essential factor in determining the classification of warehouse robots. Warehouse robots are classified by payload capacity. This depends on the industry and the warehouse's specific needs. The largest market share for warehouse robots was held in the range of 0.5 to 10 kg (1.25331 lbs to 22.04622 lbs).

 

 

Industries that use warehouse robots

 

Although warehouses from almost all industries use warehouse robots to manage their stock, some warehouses are more dependent on them than others. The increase in warehouse robot adoption results from the "growing e-commerce industry, need to enhance quality and reliability in warehouse operations and active funding from venture capitalists, and increasing adoption by small-and-medium-sized enterprises (SMEs) of warehouse robotics." As a result, markets & Markets predict that the need for warehouse robotics in the food and beverage industry will continue growing rapidly through 2022.

 

Warehouse robots are also in high demand in the automotive sector, especially the spare parts industry. Automotive companies invest in robots that can carry heavy spare parts, which is a different approach to e-commerce food & beverages. As a result, automotive companies can increase their productivity and speed up the delivery of spare parts by using warehouse robots.

 

Other industries that also use warehouse robots are:

• Electronics and electrical
• Machines and metal
• Plastic, rubber, and chemical
• Pharmaceuticals
• Apparel
• Textiles
• Printing and paper

 

How warehouse robots navigate warehouses

 

To navigate through a warehouse, warehouse robots use various navigation systems. Here are the most popular navigation systems that warehouse robots use.

Rail navigation

Rail-guided warehouse navigation robots travel along predefined routes marked on the warehouse floor.

 

Navigation by wire

Wire-guided Navigation is similar to rail-guided Navigation in that robots use a physical guide (in this case, a wire, not a rail) to navigate through the warehouse floor space. The main difference is that the cables are not attached to the warehouse floor but hidden beneath it. These robots are equipped with inductive sensors that measure the electromagnetic field's intensity and speed created by the current flowing through the wire. 

The main benefit of wire-guided navigation is that the cables are concealed in the flooring so that traffic can travel through the high-density storage without interruption.

 

Magnetic tape-based navigation

A magnetic tape-based navigation system is another navigation system. Robots that use magnetic tape-based navigation follow pre-determined paths. This is done by placing the magnetic tape along the routes. To guide robots, an environment magnetic field is created by the tape.

 

Navigation based on labels

Robots are outfitted with a 3D laser rangefinder to enable label-based navigation. Robots use the range finder data to identify objects like shelves, doors, and floors. Then, the robot's position is determined using object recognition. This data is combined with a global environment map. Finally, these robots can accept orders based on semantic labels such as "navigate the nearest door" or "navigate to that closest door."

 

Laser-based navigation

Many robot navigation systems use laser guidance, including label-based navigation, which uses 3D laser range finders to locate and recognize objects. In some cases, robots rely entirely on laser sensors to create a 3-dimensional map of their environment. These systems are often coupled with algorithms in microcontrollers or embedded processors.

 

Navigation based on a vision

Vision-based navigation is another form of navigation that uses laser sensors. It refers to any navigation system that uses optical sensors like laser-based range finders or photometric cameras with CD arrays to interpret the visual characteristics of the environment. This information is used to position and avoid obstacles.

 

Geo-guidance

Geo-guidance robots recognize their environment using sensors to determine their location within the warehouse. This allows them to identify objects like racks, walls, and pallets and choose their route.

 

LiDAR

6 River Systems' Chuck uses LiDAR to navigate. It is a highly technologically advanced method of navigation. LiDAR sensors measure the distance between robots and other objects in an environment. This data is compiled into a 360-degree map that allows robots to navigate the facility and avoid obstacles. Chuck uses LiDAR, machine learning, and AI to plan the most efficient navigation routes.

 

 

Warehouse robots: What are their uses?

 

Warehouses today use robots for many purposes, thanks to advances in navigation technology. This is how warehouses use robots to perform everyday warehouse tasks.

• Loading, unloading

Forklifts and pallet trucks are used for loading and unloading. However, AGVs such as automated forklifts can help warehouses speed up these processes. Although warehouses still have a lot of work to do before fully automated loading and unloading, robotics solutions can help with tasks like removing pallets from tractor trucks and placing them on conveyor belts.

 

The only problem with current unloading robots solutions is the modification that may be needed for tractor-trailers. This can be costly and difficult, especially for warehouses receiving goods via multiple logistics providers. Modifications are not required in these cases, but the process can be slower.

 

• Palletizing and Depalletizing

Many warehouses use pallets to ship and receive goods. However, palletizing and depalletizing can be tedious and repetitive tasks. Automated palletizing equipment is not new. However, it is gaining popularity because of the desire to reduce strain on workers from non-ergonomically pleasant tasks.

 

These solutions typically have an End-of-Arm Tool, which allows you to grab and place items on a pallet. In addition, these solutions are often paired up with conveyors transporting products to the palletizing area. Many types of robotic palletizing solutions are available, including bag palletizers or case palletizers. Some can even handle fragile items.

 

• Sorting

Although it may seem easy, sorting is challenging to automate. Warehouse robots designed to sort items must be able to pick up and identify objects and then place them in the correct bin or storage area. 

Robots used to sort warehouse items are often paired up with conveyor systems. They use robotic arms to grab objects and cameras to identify the item. Compared to traditional systems, automated sorting reduces the need for transfers, touches, and conveyors.

 

• Picking

According to Markets and Markets, picking accounted for the most significant percentage of the overall warehouse robotics market. Warehouses want to use automation technology that makes it easier for workers to do their jobs more efficiently. Labor costs account for about 65% of the warehouse's overall operations budget. Picking robots are used by warehouses in many industries. They are precise and efficient and can reduce order processing time and associated costs.

 

6 River Systems' Chuck uses LiDAR to provide flexible navigation and machine learning and AI to find the best routes in real-time. Chuck allows associates to concentrate on automated warehouse picking. It autonomously drives to and from active picking, takeoff, and induct areas and leads associates through tasks. 

 

A second benefit is the reduced walking time. After implementing 6 River Systems fulfillment, Healing Hands Scrubs saw a reduction in the walking time of its associates from 12 to 3 miles per day.

 

• Packaging

Another labor-intensive task in the warehouse can be automated with automation. Automated packaging systems, such as bagging machines, can speed up the packaging process. Cartonization software calculates the optimal carton size based on order weight, dimensions, and other data. This technology allows for a reduction in waste and labor costs.

 

• Robotic Transportation

There are many robotic transportation systems, including AGVs, conveyor systems, and monorails. Monorails are commonly used to transport pallets, while conveyors can be used for smaller items such as boxes and bins. Some conveyors can transport pallets. 

AGVs are available in customized load handling. These robots can transport goods, containers, or pallets from one place to the next in the warehouse, from loading docks to sorting zones or picking zones to packaging.

 

• Storage

Automated storage systems and retrieval systems (AS/RS) include warehouse robots such as pallet shuttles, mini-load systems, and cranes. These solutions can be used in conjunction with mobile racking systems to maximize space utilization. AS/RS systems are typically rail-bound and used in narrow spaces, such as aisles or great heights.

 

The U.S. warehouse average height grew to 33ft in 2016. This is an increase of just 24ft in the 1960s. There's also a steady move toward 36-foot clear warehouse facilities. The greater the warehouse's capacity to store more, the higher its revenue potential. 

 

However, retrieving and storing items in high-traffic areas can pose safety hazards for workers. It's also less efficient than picking up items in more accessible locations. 

 

AS/RS allows warehouses more vertical space without compromising safety and efficiency. However, AS/RS solutions can take up significant warehouse space. This is due to the need for substantial infrastructure investment.

 

• Delivery

Amazon and major corporations are interested in hiring autonomous delivery robots, namely drones. However, this technology is still not ready for prime time. There are also autonomous vehicles and variations of the concept, such as driver-assisted cars. Although warehouse robots aren't yet able to transform delivery processes, this area is worth watching.

 

• Replenishment

Drones scan barcode labels to check inventory levels and RFID 50% faster than manually sending inventory counts back into the warehouse management software. In addition, these solutions can be configured to issue alerts and assign tasks based upon triggers such as inventory count dropping below a threshold.

This can aid in automating replenishment workflows. Many warehouse management systems can also be set up to automate reordering. This will reduce backorders as well as stockouts.