Automated Load-out Logistics – RoboDock-L (carton fed) Technical Trials
The outcome of the project is to develop and integrate enabling platforms to protect high value market access. This program of work will also maximise impact in the areas of lifetime traceability, labour and WHS risk reduction related issues to loading and managing inventory and consistency of supply.
| Publication date: | 11 March 2022 |
| Project status: | Completed |
| Livestock species: | Grain-fed Cattle, Grass-fed Cattle, Sheep, Goat, Lamb |
| Relevant regions: | National |
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Summary
The outcome of the project is to develop and integrate enabling platforms to protect high value market access. This program of work will also maximise impact in the areas of lifetime traceability, labour and WHS risk reduction related issues to loading and managing inventory and consistency of supply. This will be done by automating the logistics of load-out area for meat processors, including the marshalling and loading, of both chilled and frozen cartons into refrigerated containers, as well as palletised meat cartons into refrigerated trucks. Information systems will be updated with outgoing shipments to ensure traceability and biosecurity right through to the product leaving the processor’s site. These may include customer-based systems such as their WMS, and/or industry based such as the Meat Messaging Portal for US exports. Checking and recording all bar codes with the addition of automated port marking ensures the correct cartons have been loaded. Images of the loaded product are stored to enable the processor to have a documented proof of load should this be questioned at any time. Automating these activities provides a critical link in whole-of-supply-chain traceability while also removing considerable exposure to operator injury & removing multiple labour units per shift. Product damage is also minimised resulting in economic benefits due to claims, as well as maintaining industry brand integrity to Australia’s export customers.
Objectives
The primary outcome of this project is to automate the load-out logistics in meat processing sites and to define what value capture can be achieved along the supply chain from this innovation. Through this innovation, the aim is to create new value that can support producers, processors, red meat brand owners and importers with highly efficient loadout and traceability system.
In doing so the following objectives will be accomplished:
• Assessment of sensing required for navigation in reflective, low-clearance container environment – what sensors are required? What accuracy should be achievable?
• Application evaluation for navigation of AGV tasks based on the outcomes of the sensing trials – how should the navigation system be structured?
• What accuracies and speeds are achievable with the proposed navigation in conjunction with AGV hardware (steering and traction wheels, drives, encoders, etc). Accuracies must be within limits of +/-40mm, and speeds must be within the initial cycle time modelling which enabled container loading of a 20ft container in <60mins, and a 40ft container in <90mins.
• Trialling for wireless network connectivity within the container – is safe wireless communications within a container possible? What does this framework look like?
• Assess maximum achievable cycle times and forces induced onto cartons for layer forming process – are there any issues with the proposed concept? What is the potential for carton damage?
• Assess mechanical limitations of design operating at required speeds – are there any mechanical issues with the assumptions made on the concept design?
Key findings
There were a range of key findings within this project, but based on this being a technological project, there were also some developments. These included:
1. Development of a Container Loading Navigation Algorithm that allows a vehicle to navigate inside a reefer container autonomously, without any manual intervention to map the walls.
2. Further development of the RoboLoader machine design, both mechanically and electrically, to the point where detailed design is ready to be completed.
3. An AGV platform, that when coupled with the developed navigation algorithms, is able to navigate in a reefer container to +/- 30mm accuracy
4. A mechanical and electrical design of a RoboLoader that allows for container loading of a 20ft container in <60mins, and a 40ft container in <90mins.
Benefits to industry
Based on the results of this project, there are a large range of benefits to the red meat industry that have been developed.
The main risk mitigation activity in this project included the development of a Container Loading AGV, which is able to navigate in and out of reefer containers to a high degree of accuracy. In addition, throughout this project, the RoboLoader’s high level electrical and mechanical design was extended in order to minimise the risk for processors as the next stages of this product development is undertaken. The full development of the product will result in a large range of benefits to the industry, including:
1. The removal of manual labour from the container loading process
2. The removal of workers from high-risk areas, such as in the back of containers or on busy loading docks
3. The enabler for a full end-to-end traceability system, by providing product traceability from storage into containers for export.
4. Enabler for proof of load information that allows processors to have proof to refute incorrect insurance claims due to damaged product
5. A decrease in the risk of incorrect product going into a container for export
6. An enabler for quality assurance of cartons before they go into a container for export.
MLA action
MLA in collaboration with Intelligent Robotics is sourcing options for partnership models to further develop a full Roboloader system and trial it in plant.
Future research
As is depicted in the section above, there is a large range of benefits the Automated Container Loading System can deliver processors within the Red Meat industry. Now that the major risks within this project have been reduced, the next phase is to begin the process of building a full RoboLoader system. This will include stages of how the cartons are handled, and the technology is to be developed into a fully functional system.
More information
| Project manager: | Darryl Heidke |
| Contact email: | reports@mla.com.au |
