CASE STUDY: a Warehouse Robot

Sept 2019
clock
3 min
Robotics

An autonomous warehouse robot project with 50 kg payload. The robot has IP-45 protection mark and operates both indoors and for short periods outdoors. EnCata refined the startup’s concept and delivered the industrial design, DFM and produced the prototype with all documentation. The robot competes in the same space as KIVA robots from Amazon and QUICKTRON from Alibaba.

BACKGROUND

A startup company engaged in industrial robotic automation approached EnCata with a POC (TRl-4) prototype. The startup’s team consisted of prominent software and electrical engineers.    They wanted to 1) refine their concept and progress  the industrial design, 2) optimise the BOM and 3) implement a DFM approach to start low-volume production and proceed to multiple pilot projects.

WORK

We began the project by  refining the concept and conducting  robot carriage/suspension simulations to ensure its stability and effectiveness in a variety of situations.

Having completed a multitude of various kinematic simulations and use-cases, EnCata’s engineers proceeded to finalize the concept while our industrial designers gave the robot a fashionable touch.

We tried to move away from the typical chunky straight lines of industrial robots and suggested a streamlined clean robot shape, while at the same time having the DFM in mind. Thus the industrial design phase left the customer with the covers design made with vacuum forming technology in order to reduce the robot production costs.

We worked closely with the startup team on the electrical side, BOM optimisation and components procurement. The robot implemented several essential components such as:

  • reliable motor wheels
  • lidar system
  • wireless charger
  • sensor system

After finishing the CAD design, DFM and documentation/drawings release phases, we proceeded to components sourcing, tooling design and prototype manufacturing.

The robot was then  first assembled as a ‘skeleton’ chassis. Components, electronics and wires were added later. In parallel, a mould for vacuum forming was manufactured.

The startup took an active role in robot assembly and wiring.  By the end of the project, we reached TRL-6  and the robot  successfully passed ‘field’ testing to qualify for batch production.

The result was that the startup working with EnCata made an overall leap from a proof-of-concept prototype to production readiness level (TRL-8) with DFM and a set of tooling designed.

RESULTS

Work with EnCata allowed the startup to focus on what they do best: embedded robot systems and warehouse/enterprise level software integration. We have brought the following components to deliver a reliable and cost-effective robot:

  • Concept refinement
  • Kinematic simulations
  • Industrial design
  • Design for manufacturability (DFM)
  • BOM optimisation
  • Prototype manufacturing
Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.

Learn more from our insigths

Product Development
Engineering

Plastic Injection Molding: 5 Key Considerations for Aluminum vs. Steel

Learn the difference between steel and aluminum molds while manufacturing injection molded parts. The guide for saving budget, time and enhancing plastic molding quality

Product Development
Engineering
Prototyping

Designing Enclosures with Different IP Ratings in Product Development

Learn about what the IP rating is, why it is important in design for manufacturing, and how it aids the product development process and sales.

IoT
Industrial IoT

Internet of Things (IoT): What it Means. Part 2

With IoT everywhere, understanding short-range networks is key for device design. Learn how these connections fit into devices and build your IoT device.

Have a project to do?

Fill out the form and a member from our sales team will get back to you

Thank you!
Your request has been submitted! We shall contact you shortly

Oops! Something went wrong... Try to reload this page and resubmit

FAQ

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?
Can you provide me with a certification of competence?
What level of training do your specialists have?
Is it possible for us to cooperate with EnCata’s team?
Is it possible to discuss the project with your technical team?
Can EnCata facilitate mass production?
Do you sign NDAs?
Patent or Develop first?
Does EnCata outsource electronics services?
Do you write program code, either software or firmware?
Are there hardware engineers in your team?
What should I do now that I've approached you with my project idea?
Can EnCata help me with fundraising?

Sorry for butting in, but

Knowing how important clarity is when working with contractors, we've put together a checklist to help you evaluate the development and production of a mechanical device. No need to leave your contact details - just select the option that fits you, and the download button will appear!
Redcross
Choose the option that best describes you:
Download
Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.
No, thanks