According to a publication by Statista in December 2021, the majority of B2C customers from a total of twelve European countries surveyed expect their online orders to arrive within three to five days. In the Netherlands, almost a third of customers even expect their goods to arrive within one to two days. However, expectations of speed, flexibility and transparency are also increasing in B2B commerce.

In order to meet these requirements, logistics processes within an organization must be designed as efficiently as possible. However, what is efficient today may already be outdated tomorrow. Workflows must adapt to the fast pace of requirements and demands - and the associated logistics processes must keep pace. The Austrian company Knapp offers a solution to these challenges. Open Shuttles are autonomous mobile transport robots (AMR) that take over internal transport tasks without having to adapt the existing infrastructure. Thanks to innovative fleet control software, tasks are efficiently distributed across the entire fleet of AMRs.

The travel drive

The AMRs in the Open Shuttle series are a flexible alternative to classic container conveyor technology and transport containers, cartons and trays up to 800×600 mm and a maximum payload of 100 kg. Thanks to the automatic lifting device and width adjustment, the Open Shuttles can accommodate containers of different heights and widths. They connect different storage areas with each other and also supply decentralized workstations. In addition to the intelligence provided by the software and sensors, the drive unit is at the heart of the AMR. With more than 70 years of experience in drive technology, Dunkermotoren was able to offer the right solution here.

The autonomous mobile robot is driven by two brushless DC motors from the BG 75 series. The attached controller ensures smooth acceleration and braking of the robot. A brake from Dunkermotoren's modular system, which is also integrated into the overall drive, ensures that the open shuttle stops immediately in the event of an imminent collision with other vehicles or people, which are reliably detected thanks to the integrated laser scanner.

The hub gearbox from Framo Morat in Eisenbach, which is attached to each drive, provides the necessary drive power. Together, Dunkermotoren and Framo Morat have already been able to realize many AGV projects and have been presenting a portfolio on the market since 2021 that is specially designed for the strict safety and space requirements of AGV solutions. The entire system consisting of motor and gearbox is maintenance-free over its entire service life. If the running surface is damaged or the requirements for the wheel change due to changes in the ground conditions, it can be easily replaced and serviced directly on the vehicle. With an acceleration torque of up to 42 Nm, the hub gear ensures that the Open Shuttle can move even heavy loads. The emergency stop torque of 63 Nm ensures an immediate stop in the event of an imminent collision. The special feature of the drive solution from Dunkermotoren and Framo Morat is the extremely compact design of the overall drive. The gearbox is integrated into the wheel hub and thus disappears into the drive without increasing its length.

Lifting and steering drive

The AMR Open Shuttle Fork is the model of choice when it comes to transporting entire pallets, racks or large special load carriers and has a load capacity of up to 1,300 kg. The integrated automatic lift enables the load to be picked up directly from the floor and allows the load to be dropped off at a height of up to 1.2 m. Drives from Dunkermotoren are used for both the lifting and steering movements and enable the AMR to move omnidirectionally. Thanks to the integrated CANopen electronics, the higher-level control system of the shuttle can easily address and control the drives. The lift of the load, which can weigh up to 1,300 kg, is accomplished by the most powerful motor currently available in the Dunkermotoren product portfolio. A brushless DC motor from the BG 95 series with matching planetary gearbox can lift even heavy loads without any problems. The attached E 600 brake then holds the load in the desired position. In extreme cases, the brake is also used for an emergency stop during full lifting movement. As soon as a certain safety level is reached, the engine is switched off immediately and the brake has to take over the stop. Two additional Dunkermotoren drives are installed in the Open Shuttle Fork as steering units to ensure that the vehicle never deviates from its course. The BLDC motors from the BG 66 series with planetary gears are compact and therefore perfectly suited for use in flat vehicles. Once again, the integrated electronics provide the necessary intelligence. Thanks to the CANopen interface, the motor receives the commands from the AMR's higher-level control system and can therefore implement even minimal course adjustments with millimetre precision.

The Open Shuttles can be integrated very easily into existing structures and during ongoing operations. To cover seasonal peaks, additional robots can be easily integrated into the fleet and removed again. Thanks to robust and maintenance-free drive solutions from Dunkermotoren and Framo Morat, the Open Shuttles are reliable, durable and meet all requirements for a small installation space and common interfaces.

Authors
Dunkermotoren: Stefanie Tröndle, Marketing Content Management & Stefan Tröndle, Product Manager; Framo
Morat: Felix Kneipp, Business Development; Knapp: Anna-Carina Adam, Team Leader Marketing for Industry Solutions