WAREHOUSE robot with 50kg payload

An autonomous warehouse robot with 50 kg payload. The robot has IP-53 protection mark to operate both inhouse and outside (temporarily). EnCata refined the startup’s concept and delivered the industrial design, DFM and produced the prototype with all the documentation. The robot plays on the same field as KIVA robots from Amazon and QUICKTRON from Alibaba.

A startup company engaged in industrial robots automation approached EnCata with a POC (TRl-4) prototype. The startup’s team comprised prominent software and electrical engineers and they wanted to refine their concept and move further with the industrial design, optimise BOM and implement DFM approach to start low-volume production and proceed to multiple pilot projects.

We have started the project from both refining the concept and doing work on robot carriage/suspension simulations to ensure its stability and effectiveness in a variety of situations. 

Having completed a multitude of various kinematic simulations and user-cases EnCata’s engineers proceeded to finalise the concept and the industrial designers gave the robot a fashionable touch.

We tried to get away from typically chunky straigt lines of industrial robots and suggested nice and clean robot shape, while having the DFM in mind. So the industrial design phase left the customer with the covers design which are made with vacuum forming technology in order to reduce the robot production costs.

We closely worked 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

Finished with the CAD design, DFM and documentation/drawings release phase we proceeded to components sourcing, tooling design and prototype manufacturing.

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

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

So the startup overall made an overall leap with EnCata from the proof-of-concept prototype to the production readiness level with DFM implemented (TRL-8). with a set of tooling designed.

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 different pieces to deliver a reliable and cost-effective robot, such as:

  • Concept refinement
  • Kinematic simulations
  • Industrial design
  • Design for manufacturability (DFM)
  • BOM optimisation
  • Prototype manufacturing