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Robotic unloaders

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Robotic trailer unloaders are cutting-edge solutions designed to autonomously unload trailers. They make use of advanced vision technology and robotics arms to move pick the cartons from the container and place them on a conveyor

Robotic trailer unloaders are cutting-edge solutions designed to autonomously unload trailers. They make use of advanced vision technology to identify individual cartons in the container. Robots equipped with vacuum suction cups (sometimes combined with supporting forks) grab the cartons from the container and place them on a conveyor. Worldwide there are approx. 15 vendors developing and delivering this kind of solutions like Boston Dynamics, Pickle Robots, Dexterity, XYZ Robotics and Technica.

Advantages

  • 24/7 Operation: These robots can work around the clock without breaks, increasing productivity and throughput. Robotic unloaders can operate continuously and consistently at steady speeds, without the need for breaks.
  • Reduced Injuries: By taking over physically demanding tasks, these robots minimize the risk of injuries related to heavy lifting, repetitive motions, and awkward postures. They can operate in environments that may be hazardous to human workers, such as extreme temperatures or confined spaces.
  • Reduced Labour Costs: By automating the unloading process, companies can reduce their dependence on manual labour, potentially lowering labour costs. This helps mitigate issues related to labour shortages and high employee turnover rates in warehousing and logistics sector.

Disadvantages

  • Investment and cost of ownership: The upfront cost of purchasing and installing robotic unloaders is significant, which can be a barrier for small and medium-sized businesses. Also, the maintenance fees for on-site support, software updates and remote support add up quickly. The total cost of ownership for autonomous robotic unloaders is in the range of 300 – 500k euro for 3 years.
  • Complex implementation: Installing and calibrating these robots requires specialized knowledge and expertise, which can complicate the implementation process. Existing facilities need modifications to support robotic trailer unloading operations, such as enhanced power supplies and safety fencing around the docks.
  • Limited flexibility for non-standard tasks: While advanced, robots may still struggle with very irregularly shaped or delicate items that require a human touch. Robots are not as adaptable as human workers when it comes to unexpected changes in the type or configuration of loads.

Limitations

Some containers are just not suited for automatic unloading and need to be unloaded manually. Products might be secured with nets, preventing the robot from continuing. Sometimes slip sheets are used between layers of cartons. In other cases, the robot cannot reach the carton at the top of the stack due to a cascade stacking.

Conclusion

Robotic trailer unloaders offer substantial benefits in terms of efficiency, safety, and precision. They are particularly useful in high volume operations, with a very constant level of carton quality and limited unexpected disturbances. However, they come with high initial costs and maintenance fees. Businesses need to carefully assess their specific needs, budget, and operational environment to determine if robotic unloaders are the right fit. For many large-scale operations, the advantages in productivity and safety can outweigh the disadvantages, leading to long-term gains in efficiency and cost savings.

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Traditional robots are heavy and therefore immobile. Cobots are too slow and therefore unproductive. That is why we have developed a palletizing robot ourselves. The ultimate balance between functionality, speed and precision.

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