Movu Robotics and Reesink Logistic Solutions: A powerful alliance transforming warehouse logistics with innovative solutions
Movu Robotics is proud to spotlight their enduring partnership’s success through groundbreaking projects across Europe. Highlighting their successful long-term collaboration, two flagship projects for the Weinig Group in Germany and B&S in The Netherlands showcase the partnership’s innovative approach to logistics challenges, including a first-of-its-kind venture into next-level cold store logistics. Tailored Solutions for the Weinig Group In Germany, the Weinig Group, renowned for its wood processing technologies, will benefit from a compact and high-performance automated pallet & item storage and retrieval system designed by Reesink Logistic Solutions. This cutting-edge system streamlines the flow of parts, semi-finished and finished products, significantly enhancing efficiency and reducing manual handling using a Movu atlas pallet shuttle system. The solution underscores the beauty of a unique fit-for-purpose solution in the manufacturing and processing industry. Innovative Cold Store Logistics for B&S The B&S project in The Netherlands takes automation a step further with its unique concept for a pallet-based Goods-to-Person Solution in a cold store environment. Within this project, the Movu atlas pallet ASRS, the Movu ifollow AMRs, the pallet conveying system and the FAST PICK STATIONS are combined into this unique, state-of-the-art and scalable pallet-based Goods-to-Person solution. Both the Movu atlas shuttles and the ifollow AMR’s can operate in temperatures ranging from -25 to +40°C. The B&S solution exemplifies how Reesink and Movu’s innovative technologies can be utilized to meet the stringent requirements of temperature-controlled warehousing while ensuring operational excellence. The Power of Collaboration Machiel van den Hazelkamp, Commercial Director at Reesink Logistic Solutions, states, “Our enduring partnership with Movu Robotics is instrumental in our mission to provide our customers with future-proof, next-level warehousing solutions maximizing their competitive position. The projects for the Weinig Group and B&S not only demonstrate our joint capability to tailor our standard products into unique solutions in response to our client’s specific needs but also highlight our commitment to advancing logistics technology in both standard and challenging environments like cold stores.” Future-Focused Movu Robotics and Reesink Logistic Solutions are pioneering the future of logistics by focusing on high-density storage, scalability, flexibility, sustainability, and the integration of advanced technologies. They’re leading the shift towards eco-efficient operations, ensuring their solutions can adapt to changing market demands using minimal space. By integrating advanced technologies, they’re setting new efficiency standards, making warehousing smarter and more responsive. This strategic emphasis positions them at the forefront of sustainable and flexible logistics innovations, ready to meet tomorrow’s challenges today. Leaving no warehouse behind with next-level solutions Movu Robotics, known for its innovative warehouse automation solutions, brings to this partnership its expertise in robotics and automation technology. The Movu atlas and ifollow solutions represent a significant advancement in pallet handling. With more than 50 years of experience in warehouse automation, Reesink Logistic Solutions brings a wealth of knowledge and a track record of integrating over 850 warehouse automation projects. Together, Movu Robotics and Reesink Logistic Solutions are set to redefine the standards of warehouse automation, delivering solutions that are not just efficient and cost-effective, but also tailored to the unique needs of each warehouse.
Rider mezzanine access lifts
How to get personnel and material from ground level to mezzanine level quickly, safely, and efficiently Scissors lifts have been moving men and material from ground level to higher elevations for more than 60 years. They offer a distinct advantage over vertical reciprocating conveyors because people ride industrial scissors lifts along with the materials that they are moving. This greatly enhances the utility of the mezzanines. The cost is very competitive with VRC’s and the installation can offer significant savings because industrial scissors lifts come from the factory fully assembled instead of in kit forms like elevators and some vertical reciprocating conveyors so they avoid costly field assembly by elevator installers. Only the gates and enclosures need to be assembled on-site. Three main features make industrial scissors lifts different from other kinds of lifts: Scissor lifts are fully assembled at the factory and not field assembled from kits. Scissors lifts have no external guide rails and/or pulley mechanisms to entangle riders. All the stability and lifting is provided by the scissors lift mechanism beneath the platform. Rider scissors lifts use constant pressure push buttons which means the rider operator is in constant control of the lift movement. Governing codes The International Building Code for 2015 was printed in June of 2014 and has clarified matters greatly. Chapter 30 Elevators and Conveying Systems, Section 3001.2 Referenced standards, sites ANSI MH29.1 Safety Requirements for Industrial Scissors Lifts. This clears up any confusion with other codes such as ASME17.1 for elevators, ASME B20.1 for vertical reciprocating conveyors or ASME 90.1 for other types of scissors lifts. Virtually all states, counties and municipal agencies accept the references cited by the International Building Code because they respect the rigorous (multi-year and multi-constituency) review process conducted by the ICC (International Code Council). Note that the MH29.1:2012 was the standard reviewed and accepted and that this version differs substantially from previous versions. Also, note that other codes such as those governing the height of guardrails or enclosures on mezzanines or upper floors must be reviewed in conjunction with the industrial scissors lift code. Enclosure heights at upper levels may vary in different jurisdictions. The essential ingredients of a proper mezzanine lift One of the essential ingredients of a proper mezzanine lift is a properly configured industrial scissor lift. The platform should be equipped with 42” high guardrails with mid rails and 4” toe plates. The lift platform should have electrically interlocked gates that prevent lift movement unless the lift gates are closed. The interlocked gates are not required by code but will be a common sense addition required by most municipalities and inspectors. The unit should have proximity switches or limit switches for each level. The control shall be a constant pressure pushbutton that the rider operator must keep depressed to maintain movement of the lift (the use of call/send buttons is not allowed with riders on the lift). The lift should also be equipped with an emergency down valve on the power unit to lower the lift in case of power failure. Again, this is not a code requirement, but most municipalities or inspectors will require it. Another essential ingredient of a proper mezzanine lift is a smooth mezzanine fascia. The entire surface of the mezzanine adjacent to the lift from ground level to the top of the guardrail on the upper level must be equipped with a smooth face to eliminate shear points. This may be wallboard, polycarbonate GP sheets or fine mesh. Interlocked doors & windows are allowed. A proper mezzanine lift would also include an enclosure system. The sides not adjacent to the mezzanine must be enclosed from ground level to the height of the highest guardrail in the fully raised position. The guardrail on the mezzanine and the access gates on the enclosure must be electrically interlocked to prevent lift movement when the gates or doors are opened and mechanically locked so that they cannot be opened unless the lift platform is present. The gap between the platform and the mezzanine should be 1”. The gap between the platform and the enclosure on all other sides should be approximately 3” to 4”. This gap requirement is not by code, but another common sense requirement required by most inspectors. The configuration should look like this: Advance lifts will always supply a configuration drawing after receipt of order so that users and inspecting authorities can make comments before the equipment is built and shipped. What about inspections of these lifts? Advance Lifts has studied elevator inspection forms from several states and realized that the forms closely followed the underlying elevator code. Advance Lifts then developed an inspection form following the same reasoning based on the latest draft of ANSI MH29.1. This form was then reviewed by elevator inspectors and further refined into its current form which is called the “Inspection Checklist For Industrial Scissors Lifts At Mezzanines” form AL-2010 Rev 1. This should be a big help to elevator inspectors and municipal building commissioners around the country. Landing lock option All multistage scissor lifts have some sway and some deflection inherent to their design. The BFL models typically used in mezzanine access lifts are exceptionally stout and rigid, but there still is some sway and deflection. This is by no means dangerous, but some people find this undesirable. Therefore, Advance Lifts created a Landing Lock (patent pending) which consists of two (2) locking pins that are extended into receivers when a unit arrives at an upper elevation. This eliminates sway and deflection at the loading edge of the platform. A discussion about specific applications is necessary to determine a recommendation on this option. By Henry J. Renken, Advance Lifts, Inc.
Slimline swiveling-rotary modules for large workpieces
The slimline infinite rotary units are suitable for the highly dynamic rotation of large workpieces and eccentric grippers as well as for use in screwing and coiling technology. Miniature drives and microdrives can be found in virtually all areas of automation technology and have a correspondingly wide variety of applications. These range from medical technology and laboratory automation as well as general machine construction and intralogistics to aerospace applications. In all areas, the small drive systems play a role in ensuring that the associated automation solutions function with optimum process safety, reliability, and cost-effectiveness. This also applies to handling applications. In slimline, yet high-torque swiveling-rotary modules, these drives ensure that even large workpieces are moved precisely, both in the case of fast screwdrivers and also in automatic rotary handling, assembly, and testing systems. Anyone looking for an efficient and space-saving solution for typical movement sequences that occur in handling and assembly technology, such as turning, swiveling, screwing, rolling, or coiling, may be interested in the swiveling-rotary modules of the ForTorque series from the kinematics specialist JA². This is because the slimline infinite rotary units are ideal for the highly dynamic rotation of large, high-inertia workpieces and eccentric grippers as well as for use in screwing and coiling technology. Turning, swiveling, screwing, coiling A typical application case for the miniature swiveling-rotary modules is, for example, screwing the caps on small cosmetics or pharmaceutics containers in constrained spaces on fully automated packaging lines. The modules are also suitable in cases where grippers or workpieces need to be swiveled, e.g. when assembling or separating products. Designed as a modular system, six sizes with diameters of 16, 20, 25, 35, 40 and 45 mm are available. This covers peak and continuous torques of 0.3 and 0.14 Nm to 4.0 and 2.6 Nm respectively. The inertia of the load may be between 2.0 and 200 kgcm². This provides the most suitable solution for accurately angled movement and positioning for a wide range of different handling and assembly tasks. To reduce the load on the output shaft of gearheads in the case of high external moments of inertia, the output plate of the four larger module models has an extremely rigid bearing consisting of two thin-section bearings. Furthermore, the swiveling-rotary module with 40 mm diameter can additionally be equipped with a fluidic rotary joint for pneumatics or vacuum, e.g. to supply a pneumatic gripper with compressed air. The kinematics specialists push the modular concept even further: An interesting possibility is to combine the fast rotary units with linear axes, e.g. of the QuickLab series. Matching adapter plates are available as accessories. The result is compact lift-rotary or lift-swiveling systems through to five-axis handling systems. High dynamics and precision “The drives are the heart of our modular automation system and the requirements placed on them are very high,” explains Wilhelm Jung, Managing Director at JA². “The motors must operate highly dynamically, be precisely controllable, and have suitable dimensions.” In the case of the ForTorque modules, for example, the brushless DC-motors of the B and BX4 series from FAULHABER proved convincing. The motors with their two-pole and four-pole technology are extremely compact. The used variants of the B series with diameters of 16, 20, and 35 mm are just 28, 36, and 68 mm long respectively, but deliver continuous torques of up to 168 mN in the case of the largest variant. Similar also applies to the BX4 series. “Here we use motors with 22 mm or 32 mm diameter and continuous torques of 18 and 53 mNm respectively,” reports Wilhelm Jung. The motors are used in the ForTorques up to speeds of 8,000 rpm. Different gearheads, including zero backlash planetary gearheads from FAULHABER, provide gear reduction. Ultimately, the gearhead technology with the respective maximum input speed determines the limit for the maximum motor speed. “We then select the reduction ratio according to the application,” continues Wilhelm Jung. “In this way, we can influence the extent to which the external moment of inertia is reduced by the square of the reduction. The motor can then be precisely regulated unaffected by the lever. When selecting the gearheads, we paid particular attention to the efficiency of the gearheads. Because the better the efficiency is, the more precisely the torque applied at the gearhead output can be determined from the motor current. This is a key feature, particularly in the case of screwing applications where delicate (plastic) parts need to be screwed on with a defined torque.” Single-cable technology for fault-free control All swiveling-rotary modules are connected and controlled using a standardized bayonet connector, single-cable technology, and a motion controller. In automation systems, however, the switch cabinet is usually some distance from the actual drive. “Between the motor and the controller in the separate switch cabinet, there can then be 10, 20 or more meters,” says Wilhelm Jung. There is therefore a special, multi-shielded cable that transfers the motor power and the position sensor signal between the motor and controller up to 30 m without interference. The cable is fastened with strain relief, can be plugged in, and is also designed for use with cable chains, i.e. for mobile use. Moreover, thanks to the available preassembled cable sets, the single-cable technology simplifies installation. With the motion controllers, the user has the choice because the used motors are compatible with different controllers. “We also offer motion controllers from FAULHABER,” adds Wilhelm Jung. The two companies have, after all, enjoyed successful collaboration for many years. In the above-mentioned QuickLab linear axes, for example, the DC linear drives LM2070 and LM1247 are used. They are not designed as classic “surface rotors” with carriages and guides. Instead, the forcer rod is guided within a 3-phase self-supporting coil. “This design produces an exceptionally good relationship between linear force and current and high dynamics. In addition, there are no cogging torques, thereby making the linear motors ideal for use in our modular QuickLab system,” concludes Wilhelm Jung. About the Author JA² (Jung Antriebstechnik u. Automation, see
How to select a proper dock lift for your operation
Hydraulic Dock Lifts have two advantages over other means of unloading trucks: Level unloading from the bed of a truck is safer than any other alternative, and Loading Dock Lifts are the only type of equipment that can reach from ground level to all sizes of trucks ranging from low step vans to large refrigerated reefers. There is no vehicle size that dock lifts cannot service. Once you realize the benefits of level loading with dock lifts, the next question is which type of loading dock lift system best fits your application and what options should you consider. Top of Ground Style or Pit Mounted Recessed Lift The first consideration is which of these hydraulic truck lift alternatives is best for your application. Top of Ground Advantages These units can be mounted on any flat concrete slab (units will sink into blacktop during the summer) and require no pit work. This not only avoids the cost of a pit, but also drainage issues and potential interference with underground utilities. If you decide to move the unit later (we have reports of units providing as many as 35 years of continuous service) it is an easy matter to unbolt the unit and move it with no pit left to fill in. Capacities range from 4,000 lbs. up to 15,000 lbs. and platform sizes range from 6’ X 6’ up to 8’ X 12’. The cost of top-of-ground units are always higher than the cost of recessed units, however, when the cost of pit construction is added to the equipment prices, top-of-ground units can be competitive. Recessed or Pit Mounted Advantages The equipment costs for these units are always less expensive than top-of-ground units. The biggest advantage is the fact that these hydraulic dock lifts are mounted flush with surrounding surfaces so they do not become an obstacle to drive over traffic. This is especially important if the unit is being mounted in a doorway. Top-of-ground units have ramps that transition loads from the platform to ground level which is fine for offloading operations but can be tiring if heavy loads must be pushed up the ramps for loading trucks. Standard capacities of recessed units range up to 20,000 lbs. Recessed units offer level loading both at ground level and at truck height. If recessed units are mounted within the face of docks they can provide easy dock-to-ground access, although top-of-ground units can do the same if the approach ramps are shortened and the units are mounted immediately adjacent to the dock. Platform Size The platform size is primarily determined by the type of transport equipment that will be used to load or unload trucks. The minimum suggested platform width is 6’. Guardrails use 4” to 8” of usable platform width on some models and there should be at least 4” of clearance on each side of the widest load such as a 48” wide pallet for ease of maneuvering. In some cases, the loads may be wider and some users like to unload two pallets side by side so 7’ and 8’ wide platforms are common options. If the loads are four-wheeled carts or baskets, or the loading equipment is limited to two wheeled hand carts, then a 6’ platform length is sufficient. For manual pallet jacks, 8’ platform lengths are considered minimum. Powered pallet jacks work best with 10’ lengths to comfortably fit the load, powered pallet jacks and operator all in line. Straddle stackers also fit well on 10’ platforms. Fork trucks are much longer so they generally require platforms in the 10’ to 12’ range. The size range mentioned above covers 99% of all applications and is now available as standards in both top-of-ground and recessed styles of loading lifts. Unusual loads may require custom-designed units with platform widths of 10’ or 12’ and platform lengths of up to 65’. If you have special requirements, a full-service supplier can help you design a perfect fit. Capacities Lifting Capacity Once a platform size has been determined, it is a simple matter of adding up the maximum weight of the goods being transferred, the weight of the transport equipment and the weight of an operator to arrive at a lifting capacity. Axle Rating Capacity The axle loads on manually propelled carts and pallet jacks are too light to be of concern. Manual pallet jacks divide payload weight evenly between two axles, but powered pallet jacks and straddle stackers often concentrate 60% of the combined payload and equipment weight on their rear axle and they can move heavier loads than manual equipment. Fork trucks usually concentrate 80% of the maximum payload plus fork truck weight on the front axle, but some unusual trucks may run as high as 90% concentrations. Most manufacturers have appropriate end load axle ratings for corresponding maximum lifting capacities, but there is always the danger that you have unusual equipment and/or if your application requires traveling over the side of the lift in anything other than the fully lowered position, there is a possibility that the side axle rating is marginal. It is wise to compare the axle loads produced by your equipment vs. the rating of the dock lifts to be safe. Roll Over Capacity This only applies to recessed units and refers to the maximum axle load allowable for vehicles driving over a fully lowered lift. Most recessed dock lifts are rated for 10,000# axle load slow speed drive over. This is usually more than adequate because of state mandated limits on truck axle loads. However, large specialty vehicles and high capacity fork trucks with small hard wheels can exceed these limits. In those cases, warn the lift manufacturer and they can modify the lifts to accommodate larger loads with thicker deck plates and other forms of reinforcement. Power units and controls The up-down controls must be controlled by the operator riding on the lift. Any other scenario is a sure recipe for an accident. Standard controls for most companies are NEMA 4 pushbuttons. These are
How to select a filter fan based on application conditions
From electrical equipment to environmental considerations, here are expert tips for smart selection What are filter fans? Filter fans protect electrical enclosures from external environmental damage. From heat control to mitigating the ingress of liquid and solid objects, filter fans provide another layer of protection for the electrical equipment housed within enclosures. Filter fans protect critical equipment by reducing thermal load and filtering out airborne particles larger than 5 microns. The dual fan and filter composition keeps electrical equipment running at optimal temperatures while mitigating the amount of dust and other particulate matter from causing buildup and damage. When selecting a filter fan for an enclosure, it’s important to consider the application’s heat load, optimal temperature, and environmental conditions in which it will be operating. Environmental considerations are particularly important for outdoor enclosures, as rain, snow, ice, and sunlight all pose risks to electrical equipment. Challenges for outdoor applications Filter fans are necessary for a wide range of outdoor electrical equipment. Some applications, however, require intentionality and extra consideration when choosing the appropriate filter fan. These include irrigation pump panels, water, and wastewater, lighting control boxes for traffic signals or fields and stadiums, outdoor communication and information technology structures, energy storage and charging systems (such as in electric vehicles), and transportation systems, including bridges, toll stations, and electrical rail equipment. When properly designed and integrated, outdoor filter fans can provide an energy-efficient solution for heat load maintenance while also protecting enclosures from dust, ice, water, and sunlight. However, many filter fans on the market do not effectively protect critical electrical equipment. When improperly designed, filter fans can be subject to ice and dust buildup or damage from UV radiation and rainwater. These conditions can cause short-circuiting within the enclosure. While there are workarounds for water infiltration, such as adding a rain hood, these additional steps increase space requirements and initial investment costs. Tips for selecting the correct filter fan Given these challenges, there are some tips to keep in mind when selecting a filter fan for an outdoor electrical enclosure. Consider heat load and environment Selecting an outdoor filter fan begins with determining the application’s heat load and airflow requirements while considering environmental exposure. Electrical enclosures in dry, hot weather require different filter fan needs than those used in areas with snow, ice, and highly variable temperatures. For applications where environmental conditions cannot be determined ahead of time, a filter fan that can accommodate each of these possibilities is best. While determining application needs, it is beneficial to consult with an expert to help determine specific risk factors. An expert can help with considerations around which airborne particulates are present and if they are corrosive, as well as what ambient temperatures can be expected and how direct or indirect sunlight can affect operating temperatures. The Pfannenberg Outdoor Rated Filterfan® (NEMA 3R rated) is designed for outdoor weather where direct sunlight and extreme weather, like rain and ice formation, are important factors. This filter fan utilizes UV-resistant plastics to prevent premature degradation from direct sunlight. Additionally, the filter fan’s design protects against the ingress of falling dirt, rain, sleet, snow, and even external ice formation. Weigh maintenance needs Filter fans generally require little maintenance outside of regular filter replacement. However, it is crucial to change the filter as specified by the manufacturer as filter clogs reduce airflow, causing extra strain on the fan and increasing the potential for overheating. Well-designed filter inserts, including the filter for Pfannenberg’s Outdoor Rated Filterfan®, described above, provide longer service life. Pfannenberg’s fluted filter-mat enables longer mean time between maintenance, delivering three times longer service life than standard designs. It accomplishes this with its increased dust-holding capacity. As a result, the need for service is reduced, saving maintenance time, costs, and stress, which is especially helpful for electrical enclosures located in remote areas. Balance protection, airflow, and initial investment costs Filter fans for outdoor applications require a design that balances airflow optimization with low initial investment. A filter design that minimizes maintenance needs should also ensure unrestricted airflow throughout the fan’s service life. However, it must do so without compromising on water and dust protection capabilities. Combining a filter that fits these needs with a filter fan housing design that does not require metal rain hoods, achieves an excellent balance of protection, airflow management, and minimizing upfront costs. Conclusion Filter fans are critical for protecting electrical equipment from overheating, water, and airborne debris so the equipment can run safely and efficiently. In outdoor environments, this task is particularly challenging. Finding a filter fan suitable for outdoor environments without significant drawbacks requires careful research. By considering heatload, environmental conditions, and maintenance needs before selecting a filter fan, it is possible to keep costs low. In applications ranging from pump panels and lighting control boxes to communication technology and energy storage systems, well-designed filter fans keep outdoor electrical equipment functional and safe. By Lucas Faulkner, Solutions Engineer, Pfannenberg USA
New Lucas Systems Market Study reveals game mechanics can drive employee engagement
Gamified workplaces entice 84% of warehouse workers Warehouse workers who play together, stay together, according to market study insights released today from Lucas Systems, a distribution center technology company providing software to workers in more than 400 warehouses worldwide. In the study – which polled 750 U.S. and UK on-floor warehouse workers – nearly 84% of workers said they were more likely to stay with a company that developed workplace competitions around their day-to-day tasks. Workers like gamifying their work; they embrace the benefits gamified teamwork could bring; and they are eager to participate if it means earning company recognition or prizes such as company merchandise. The study explored how workers feel about game mechanics such as workplace competitions, rewards, teamwork, and leaderboards. These game mechanics are tasks that govern the actions and responses of gameplay. “The results point to new and innovative ways for managers to attract and keep warehouse workers,” says Lucas Systems Chief People Officer Bud Leeper. “Employee engagement comes from good relationships, recognition, satisfaction of achievement, and having some fun – all of which can be enhanced through workforce gamification.” Lucas Systems says the time is right to implement warehouse gamification as 98% of workers (regardless of age) have some experience with game mechanics at work and 94% already participate in games in their personal lives. Gamification can be a differentiator for employers looking to fill the more than 250,000 warehouse worker job openings in the U.S. right now. Other market study insights: Workers embrace competing as a team, as it puts less pressure on individual performance. Top motivations include strengthening the team (57%), the opportunity to engage with more co-workers (55%), and learning from teammates (53%). 88% said they are comfortable with day-to-day performance measures being shown to other employees. Boomers are generally lowest in comfort level, but still, over 80% favorable. There is strong acceptance of game mechanics, regardless of generation. Among non-supervisor warehouse workers, Gen Z are the most enthusiastic about workplace competitions. An overwhelming 90% would participate for a 10% cash bonus or lower incentive, dwarfing the already enthusiastic 77% of Gen X workers who say the same. “Warehouse operators can turn repetitive day-to-day tasks into more fun but that should be done thoughtfully and with the worker at the center,” adds Leeper. “It’s a trust exercise between workers and management. Workers must trust they will benefit from participating.”
What is a Lithium Battery Digital Passport?
A digital battery passport provides easy access to structured, reliable, and complete information about the battery. This fresh initiative in the U.S. lithium battery landscape aims to simplify the choice and use of batteries for consumers. The U.S. government agencies are working on battery passport requirements, centralizing battery specifications and pertinent details, making it user-friendly for the everyday buyer. This digital battery passport offers a streamlined gateway to trustworthy and comprehensive battery data. Its widespread embrace is important for battery industry growth, pioneering products, safety, and environmental stewardship. As U.S. government bodies shape this directive, those in the electric industrial equipment sector can reference the EU’s recent regulations for insight. But, what exactly is a digital battery passport? Digital Battery Passport provides transparency, rewards responsibility A digital battery passport is a unique file created for each battery that contains complete information about the battery, its components, technical specifications, telemetry data, service history, expected life, etc. It is provided by the manufacturer to authorized operators. For companies operating electric industrial equipment, easy access to complete battery data translates into higher efficiency in their fleet management and equipment utilization. It also makes corporate ESG and emissions reporting easier. Supporting the development of a competitive, innovative battery market Structured and complete information helps operators increase battery serviceability and take the guesswork out of decisions on whether a battery is compatible with particular equipment. The data about installed integration protocols provides easier market access for new battery products, and fosters competition and innovation. Access to BMS data and software can help update CAN integration protocols with a charger and host vehicle or repurpose a battery for a subsequent application. Equipment utilization, reusing, and repurposing of lithium batteries The current lack of transparency in any battery’s actual state of health (SOH), expected cycle life, maintenance, and service history is a barrier to improving equipment utilization. This data can also help to define battery compatibility with secondhand equipment or repurposing. Reliable and easily accessible battery data will reduce the cost of testing and evaluation and help recover the residual value of a used battery. Ensuring a high level of environmental protection in the USA Manufacturer and user ESG claims can be substantiated with verified information on battery key specifications, such as cell chemistry, the origin of the core battery materials, the share of recycled materials used in manufacturing, and the full cycle carbon footprint. Supporting the growth of renewable energy sources, reducing CO2 emissions Testing and evaluating cells in used Li-ion battery packs is a bottleneck in the emerging business of re-manufacturing EV batteries for solar energy storage applications. Accurate battery data helps solve the problem of battery evaluation, reducing the cost of repurposing batteries for solar energy storage, and supporting the growth of renewable solar-generated electricity. With fewer batteries to recycle, the energy usage for recycling and waste management is reduced, resulting in fewer CO2 emissions. What are the main requirements of the recent EU “battery passport” regulations? The new EU “digital battery passport” regulation came into effect on 08/17/2023, with a planned start date of 02/18/2024. It introduces a few major demands for the batteries sold in the EU and is a good precedent for the US business community to study and learn from. All battery packs having a capacity over 2 kWh will need to have a digital battery passport to carry a disclosure of the CO2 footprint over the battery’s full life cycle, and to allow for user access to data on the battery’s state of charge and the number of cycles left in the battery before end-of-use. New rules have been introduced for repurposing and recycling, as well as a requirement for a minimum content of recycled metals used in manufacturing (cobalt, nickel, lithium, and lead). We wrote about how the data capabilities of forklift lithium batteries in the US can provide a solution to help EV car buyers and sellers deal with the current obscurity of battery health. Digital battery passports are a big step forward in solving this issue. Sustainability and Safety All rechargeable industrial batteries with a capacity of more than 2 kWh must have a “clearly legible and indelible” carbon footprint declaration and a label indicating (amongst other information) the levels of recycled cobalt, lead, lithium, and nickel used in the production of that battery. Digital battery passport EV batteries and rechargeable industrial batteries with a capacity of more than 2 kWh will need a “digital battery passport,” with information on the battery model, the specific battery, and its use. More generally, all batteries must have labels and QR codes detailing their capacity, performance, durability, and chemical composition and show the “separate collection” symbol. For batteries using a battery management system, the end-user should be able to determine the state of health and expected lifetime of such batteries at any time based on the data stored in the battery management system. This data should be updated at least daily, or more frequently where that is required for a specific purpose. Recycling / End-of-Life Management The battery management system of EV batteries shall include a software reset function, in case enterprises carrying out preparations for the re-use, repurposing, or re-manufacturing of EV batteries need to upload different battery management system software. Benefits of a mandatory digital battery passport for US users and dealers of industrial equipment A unique “digital passport” can reduce the complexity and minimize the risks of choosing, buying, and servicing an industrial battery for US customers. On the other hand, excessive regulation runs a risk of stymied product development and price increases. Some US battery manufacturers, like OneCharge, have already developed digital passports for their batteries giving users access to the battery data. What are the data points they can provide today? Digital Battery Passport Datapoints Each OneCharge battery is Wi-Fi-enabled and provides authorized users with complete, up-to-date battery data, including the following data points: battery model and serial number—these help consumers identify the battery and to find information about it online or in
Over-The-Dock Racking: Special considerations for busy loading zones
When it comes to optimizing space in a warehouse, distribution center, or production facility, safety should always be the top priority. One often overlooked area that can provide a cost-effective solution for the need for additional storage is above the dock doors. Although inbound and outbound dock areas are a hub of activity, a properly engineered and protected rack structure can leverage the unused area above the dock doors to free up floorspace. For operations thinking of using over-the-dock racking, here are a few special considerations for their safe application in busy loading zones Consideration # 1: What Are the Stored Items Many operations utilize over-the-dock racking to store items that are useful to have near the dock. Often, this is an ideal place to put empty pallets, said Dawn Bigbee, Design Supervisor at NUCOR Warehouse Systems, a member of the Rack Manufacturers Institute (RMI). “We often see over-the-dock racking used to hold pallets that are waiting for a return trip to a customer or a vendor,” she said. “This helps open up floorspace in the dock area by allowing them to be stored overhead.” Likewise, other operations use over-the-dock racking to store excess inventory of packing and shipping materials, Bigbee continued. “I’ve also seen operations use this as the spot to store facility-related items, like extra lightbulbs. It’s a good location for long-term storage of items that don’t require frequent access or movement.” Consideration # 2: Structural Capacity of the Rack Configuration As with every rack installation, safety is paramount when implementing over-the-dock racking. Bigbee urged operations considering this solution work with a qualified rack design engineer to ensure the safest structure. There are three typical over-the-dock storage rack solutions available. Conventional single-deep selective pallet rack with uprights located on either side of the dock doors. The first level of storage beams and decking are immediately above the doors. However, because of the heavy forklift traffic passing in and out of the dock doors when loading and unloading trailers, many operations prefer to minimize impact risk. There are two rack design alternatives that can accomplish that goal in busy loading zones, said Bigbee: single-leg pallet rack and suspended pallet rack. “In both of these situations, however, the rack must tie in to the building wall,” she explained. “That makes the design of these two types of over-the-dock racking more complicated structurally, because now the loading forces will be applied to the wall. That additional load can damage the building’s structure.” To safely and properly design these styles of rack requires consultation with the building’s original structural engineer. That can be challenging when working with an existing building, she said. “It may not always be possible to locate the facility’s structural engineer — particularly in an older building,” Bigbee noted. “If you can find that person, they need to confirm that the building’s walls can handle the applied loads imparted by the rack. But it’s often challenging, particularly in older facilities.” For that reason, the optimal time to plan for single-leg or suspended over-the-dock racking is during the design phase of a new facility. Regardless of whether using over-the-dock racking in a new building or as a retrofit, the rack structure will need permits issued by the local jurisdiction. Consideration # 3: Protecting Uprights and Personnel Installing safety and containment accessories will help protect the racking from forklift impacts and prevent items from falling into the busy loading area. Pallet rack column guards — offered in a variety of configurations — deflect impacts. Bollards and guardrails are free-standing versions of these protective guarding devices. They are installed on the floor a few inches in front of the uprights. Other column protection options are either bolted or welded to the column. Outfitting over-the-dock racking with flexible safety nets or rigid steel mesh panels protects personnel working in the area from falling items. These containment accessories capture any items before they tumble to the floor. “Like all other industrial steel storage rack installations, plan for routine inspections of over-the-dock racking for damage,” added Bigbee. Because these racks will be in a high-traffic area, inspections should occur daily to identify dents, missing safety pins, loose anchor bolts, and more. Immediately isolate the area until repairs are complete. Want More Pallet Rack Safety Guidance? RMI offers multiple resources detailing both standards and best practices that enhance people and pallet rack safety. This includes a series of videos, presentations, publications, case studies, frequently asked questions, and an MHI Cast podcast recording about rack safety. TAGS BEAMOVER-THE-DOCK RACKINGPALLET RACKPROTECTIVE GUARDINGRACKRACK DAMAGERACK GUARDINGRACK INSPECTIONRACK MANUFACTURERS INSTITUTERACK SAFETYRMI
BSL Battery: Industrial expands testing and product validation capabilities
Ground support equipment (GSE) is traditionally powered by internal combustion engines (ICs), just like the aircraft they support. The burning of diesel, gas, or propane, however, results in carbon emissions that negatively impact the environment. Airlines and airports are replacing diesel-fueled ground support equipment (GSE) with lithium-ion battery-powered machines to meet evolving environmental requirements. By switching from diesel-fueled equipment, we reduce carbon emissions, fueling and engine maintenance costs, as well as the health risks associated with internal combustion engine emissions and noise. BSL Battery – Industrial Expands Testing and Product Validation Capabilities with Field Shaker To make sure the truck is “revived” immediately and the life expectancy is excellent after a “heart transplant”, BSLBATT Battery team conducts strict performance tests to assure all BSLBATT battery products meet industrial standards for quality and compatibility for every applications. Announcing Last month an expansion in-house with all the testing required to meetUL 2580 and UN/DOT 38.3compliance Testing and product validation capabilities for equipment, including field shakers. To learn more about UL 2580 testing and UN38.3 certification with BSL Battery – Industrial, keep watching our video or read on! As they work to convert their existing ground support equipment into more energy-efficient electric vehicles, key players in the aviation industry support the development of these safety standards.Retrofitting lithium-ion batteries into more traditional diesel-powered equipment when upgrading existing fleets is also addressed in the Standard. Most ground support equipment today is powered by gasoline or diesel engines, and some by lead-acid batteries. Emissions from internal combustion engines can harm the environment and ground personnel. Over the next three decades, airports around the world have committed to removing all diesel-powered vehicles from their apron and airside. A $640,000 (USD) grant was awarded by The Chicago Department of Aviation toward United Airlines’ $1.43 million (USD) joint investment with the Environmental Protection Agency to purchase 26 new zero-emission GSE vehicles.United Airlines will save more than 1.4 million gallons of diesel fuel and reduce emissions of carbon dioxide (CO2), the primary air pollutant in the generation of greenhouse gases, by more than 16,000 tons (as well as other byproducts of fuel emissions). The Voluntary Airport Low Emissions Program (VALE) offers financial incentives for airports to reduce their carbon emissions.According to the FAA, this program has funded 121 projects at 56 airports since September or 2020.Many airports around the world are eligible for grants. Retrofitting GSE lithium batteries Some aviation GSE is already powered by lead-acid batteries. However, lithium batteries are significantly lighter, smaller, and offer better energy storage and physical space than lead-acid batteries. Because of these reasons, the aviation industry is retrofitting its lead-acid-powered GSE fleets with lithium batteries. Since lithium retrofit batteries are not closely regulated, the aviation industry is particularly concerned about their safety. In order to address this concern, the Standard provides for the retrofitting of lithium batteries into more traditional diesel and lead-acid powered equipment. Maintenance and operations at airports Unlike lead-acid batteries, lithium batteries require no maintenance other than charging. Due to the prevalence of lead-acid powered GSE in their fleet inventory, most airline operations facilities already have charging equipment. Lithium battery chargers, new battery charging stations, and their facilities can be tested for safety compliance and for fire, electric shock, and explosion risks. In the aviation industry, managers of dangerous goods and ground support teams agree that prevention is the best way to increase safety. Haley Ning said: “UL’s comprehensive testing facility enables in-house qualification of everything from the smallest to the largest battery system, eliminating the need to outsource any testing aspects of UL or UN certification and speeding up the process. ”BSL Battery – Industrial Chief Operating Officer. “Our strong relationship with UTL, an Underwriters Laboratories compliant laboratory, coupled with these strong testing capabilities, enables BSL Battery – Industrial to rapidly develop and deliver world-class energy storage systems to critical applications for our end users. All BSL Battery – Industrial systems are designed and tested to meet the rigorous standards of the modern operating environment, with an unwavering focus on safety and reliability. We remain committed to providing clean energy solutions to this fast-growing market.” Lithium-ion Transition The first step in implementing lithium-ion battery technology is to assess the condition of the current fleet of ground support equipment. Consider these questions as a starting point: Is there equipment that is nearing the end of its useful life that would need to be replaced? Could you easily replace the lithium-ion battery pack on your existing electric GSE? You should evaluate the specifics of the fleet operations once you have answered the first two questions: What is the average number of hours per day that the GSE is used? Is there a requirement for battery charging infrastructure? What are the environmental and regulatory requirements? (not just today, but in the future as well) A detailed return on investment (ROI) calculation can provide insight into the economic benefits of switching to a lithium-ion or lead acid power source. Don’t forget to include maintenance costs, battery replacement costs, and refueling/charging infrastructure costs when calculating the total cost of ownership. GSE with zero emissions and high performance is in high demand. Because lithium-ion batteries provide significant benefits, IC engines are increasingly being replaced by lithium-ion batteries. In light of government regulations on emissions, now may be the right time to start looking at high performance lithium-ion batteries for GSE fleets.
Lithium forklift batteries make a good business case for rental dealers and renters
The electric forklift rental business model benefits greatly from switching the equipment to lithium batteries from widespread lead-acid batteries. Lithium batteries have longer lifespans, are more economical and durable, and require less maintenance, resulting in improved profitability for forklift dealers and helping customers achieve their sustainability objectives. As forklifts become increasingly electrified and rental fleets expand, lithium batteries are a wise investment for both dealers and renters. Long-term rental of forklifts When renting forklifts for extended periods, the switch to Li-ion batteries provides similar advantages as leasing or buying own equipment. These benefits can be summarized as follows: Reduction in labor costs for maintenance (no need for daily watering and synchronization charges), resulting in 20-40% savings on the total cost of ownership of material handling equipment. Lower electricity use, leading to lower carbon emissions during operations, due to higher efficiency of energy conversion of lithium batteries. Improved overall efficiency in operations with less downtime and better forklift performance. A cleaner and safer workplace when compared to using flooded lead-acid battery packs. Companies may choose to buy new or select used electric forklifts in online classifieds and get all these benefits of lithium technology. But what about those operations that opt for short-term rental of their forklifts? Short-term rental of forklifts When it comes to renting forklifts for shorter periods of time, dealers face unique challenges. Renters have no incentive to invest in the proper maintenance of the batteries, often neglecting to water them regularly or synchronize their charge, returning them “dry” at the end of the lease term. The renter is required to run the tests and discuss the potential reimbursement for the damage and service labor, which no one likes to do. Here is how Eddie Burke, President and owner at Combilift Depot in Houston, TX, describes the problem: “We rent equipment all over the country, and can’t send technicians for daily watering. Most machines are rented out monthly, and when they come back, we inspect the battery, if it is damaged it is hard to determine whose fault it is… You can’t prove (if it is the customer’s fault), and I don’t want to argue with the customer over the damage to the battery. We are switching to li-ion, so the conversation is more like – “Is there a hole (in the battery)? No? We are good!” It’s just so much easier to do the testing (of a lithium battery) and make the judgment call.” Combilift Depot spends 4-6 hours of technician labor per lead-acid battery for diagnostics and service each time it is rented out and returned. Taking into account the much longer cycle life of a lithium battery, the savings are impressive. Eddie Burke continues: “In a perfect world a well-maintained lead-acid (battery) lasts 5-6 years, in rental conditions, it is great if it gets to 2-3 years when you start replacing cells. With OneCharge Li-ion (battery) we expect 10 years (of cycle life), it is a no-brainer”. A dealer would typically sell used equipment after 5 years, and the value of a lead-acid battery by this time is zero. With an advanced forklift battery, such as OneCharge, a buyer gets a full picture of the cycles left in a battery and can calculate how many years it can be expected to power the truck he buys. Rental contracts can be irregular, and if left idle for even a few weeks, a lead-acid battery can lose its charge and suffer permanent loss of capacity if not cared for properly. The worst thing that can happen to a lithium battery is if an operator forgets to charge the battery pack. Compared to lead-acid batteries, lithium-ion batteries are much more energy-dense and do not lose voltage with discharge. This means that a lithium battery with a lower Ah capacity can still cover most needs of a diverse pool of forklift renters, significantly reducing the cost of purchasing batteries for dealers. Additionally, lithium battery chargers are much smaller and lighter, which makes them easy to install or wall-mount around the facility. Growing popularity of equipment rentals In a recent article published by Forkliftaction, Rod Dayrit – the Business Development Director at Delta-Q Chargers – highlights the increase in equipment rental growth. He explained that forklift buyers see very long lead times for new equipment, and dealers are facing challenges in meeting demand due to economic factors such as high inflation rates and supply chain disruptions. Due to the rising costs and low availability of the new equipment, more and more end users are opting to rent instead. This helps them have fixed costs, and avoid potentially depreciation costs related to the unstable economic situation. Eddie Burke says the growth of the rental business started before COVID, but has accelerated in 2020: “We’ve seen a steady increase over the last 5 years. The current economic uncertainty with a war starting in one country and a government overthrown in another, with the US presidential election next year, pushes customers towards the rental model”. According to the American Rental Association (ARA), equipment rental revenue in the United States is expected to continue growing. In their 2023 update, the ARA projected a 7.6% increase, which would amount to $60.4 billion in revenue for construction and general tool rentals. Conclusions Lithium forklift batteries offer unique benefits for the burgeoning market segment of forklift fleet rentals by completely eliminating the pain of irregular service and maintenance. Lower required capacity, long cycle life, and significant savings on the total cost of ownership help accelerate the electrification of equipment and improve dealers’ bottom line while helping their customers achieve their sustainability and safety goals. Eddie again: “For the renters, the change to lithium (technology) means no maintenance, no obligations to watering, which is always a big mess, lower electricity use, and no damages discussions. And – safety guys do not like lead-acid batteries!” About the Author: Tim Karimov, President of OneCharge Lithium Batteries
BSL Experience – BSL dealerships use Lithium-ion technology in sales and service
BSL recently interviewed Director Winston Suhermin of Bekasi – West Java Indonesia forklift dealer PT. Sarana Mitra Luas Tbk. We sat down with him to learn about their business and how the BSLBATT lithium-ion battery pack has changed their business. BSL: Can you give a quick overview of your company? Winston Suhermin: My name is Winston Suhermin, I am the Director of PT. Sarana Mitra Luas Tbk. I have been with the company since 2020. PT. Sarana Mitra Luas has strived for excellence since 1996. Started as a small forklift rental company based in Cikarang, to one of the most reputable forklift rental companies in Indonesia with a fleet of over 3500 units; the key was simple, “Customer Obsession and Operational Excellence.”In PT. Sarana Mitra Luas, we have a massive obsession with customer satisfaction combined with a deep passion for innovation. We strive for the best customer experience because we don’t just provide forklifts. We provide solutions. BSL: How long has your company been in business? WS: All forklift sales and rentals in material handling equipment have been around since the early 90’s. BSL: How many sites do you service? WS: We have built a strong network of customers all across Indonesia in locations such as Jakarta, Bandung, Cirebon, Semarang, Jogja, Surabaya, Lampung, Palembang, Jambi, Riau, Medan, Batam, Padang, Banten and Pontianak. BSL: What is unique about your dealership? WS: I would have to say our service support is really what differentiates us. We are the No.1 rental company in Indonesia with more than 3500 units of material handling equipments and served more than 15 cities in Indonesia. With our 27 yearsof experience, large enterprises such as Sinarmas, Indofood, LG, A etc have trusted their material handling needs to us because our main priority is good service and customer satisfaction. Because we do not only provide forklifts, we provide solutions. BSL: How long have you been working with BSL Battery? WS: We have been working with BSL BAttery for about 3 to 4 years. BSL: What challenges did you come across in your industry that led you to look for lithium-ion solutions? WS: Lithium-ion started growing more popular because of their ability to fast charge, no maintenance, and their long lifespan. We started to sell lithium around 3 years ago when we were approached for a project. We also had many of our customers asking about lithium which made us decide to pivot our business to supply and service lithium batteries. From that point on we have learned a lot about the technology and which lithium suppliers are the best, took a chance and tried BSL-BATT. BSL: What makes lithium-ion a good fit? WS: Well, I like to look at customer application. Do they have multi-battery operations? What is their usage? Do they do a lot of maintenance? Can they benefit from opportunity charging? From there I will look to see if there is opportunity for them to eliminate space, eliminate maintenance, and eliminate the fumes during charging. If all the boxes are checked off, I offer lithium. Most customers come in knowing and pushing to try lithium-ion technology. Sometimes customers want the technology even though it doesn’t make sense to integrate it in their application because of the low equipment usage in their facility. But these days businesses want to go green and that is probably the biggest push when customers come to me looking for a lithium-ion battery. BSL: How did you determine that BSL Battery was a good fit? WS: We started using other competitor batteries and we never got the best support from them. Our customers were just having too many issues with other battery supplier’s batteries. BSL battery’s excellent products and after-sales support helped us a lot, I like their excellent ability! BSL: Can you describe your selection process of why you chose to partner with BSL Battery? WS: The key to our success is very simple, “customer satisfaction and best service”. at PT. Sarana Mitra Luas, we focus on innovation to improve operational performance efficiency and provide the best service to our customers because we are not just a forklift provider, we are a solution provider. We really do want what is best for my customers, so we only want to sell the best product on the market. BSLBATT has outshined everyone with their product support, quality, and design. Especially the battery management system (BMS) and telematics. I base what type of lithium-ion batteries I sell by the battery supplier’s BMS. If the BMS is designed well it makes servicing the battery smoother and the customers don’t lose productivity. Different lithium battery suppliers have different BMS. Some are harder to service than others. secondly BSLBATT Automotive Grade Modules are fabricated out of commercial grade steel. The lithium battery modules are retained by nickel plated busbars to ensure long-term performance. They are designed to withstand freezing temperatures through the use of premium components and controlled by onboard computers that keep your forklifts operating even in cold storage applications. Not only does BSLBATT have a quality BMS and Automotive Grade Modulesthey have some of the best support when it comes to customer service. BSL: How do you measure the value that BSL Battery products provide? WS: To help OEMs, BSLBATT has developed 43standard modules for lithium batteries of different capacities, which can form parallel building blocks in forklift battery compartments. Up to 20 of these modules can be stacked in parallel, and the total capacity can be tailored to forklift OEM needs. The BMS and telematics measures it all. It makes servicing 10 times easier. Customers can make decisions to improve operations based on the data they see. BSL: What is your overall opinion of lithium-ion vs the traditional lead acid battery? WS: I am completely surprised by the efficiency, longevity, and the fast-charging capabilities lithium has compared to lead acid batteries. Quality & function wise, It is far more superior than regular lead-acid battery. As I said before, It has a lot of advantages in which lead-acid batteries don’t. Such as fast charging, longer life-cycle, maintenance free, opportunity charging, etc. But price is the only problem, it is far more expensive :’) Yes, the upfront cost of them is high, but what you
BSLBATT Lithium Battery Factory -Nothing is Impossible
China’s manufacturing displays great power across the world. As one of the leading lithium Battery manufacturers in China, Specifically designed for perform in multi-shift warehouse applications. Here at BSLBATT Battery we have been growing rapidly across our global dealer network and this means we have been developing our manufacturing to accommodate this. Our Factories all play different roles in manufacturing the BSL Product portfolio from start to finish and are a colorful display of the process of bringing our products to the #materialhandling market! About BSLBATT factory The BSLBATT factory currently has three bases in Huizhou, Guangdong, Dongguan, and Jiangxi in China. The total land area of the existing production base is about 12,000㎡. Our current total production capacity is 2.5 GWH. Among them, energy storage batteries accounted for 1GWH, Motive Power lithium batteries accounted for 1GWH, 12V lithium batteries, and lithium batteries in other special fields accounted for 0.5GWH. Each BSL lithium battery is mainly composed of cell material selection, cell combination, module, laser welding, assembly, measurement, BMS, debugging, sealing, debugging, testing, aging, labeling, communication, inspection, packaging, and delivery 17 processes complete the manufacturing. 1000 sets of equipment on the assembly line including laser welding, module line, testing line, and packaging line work continuously. In recent years, BSLBATT is adding a new type of automation line, which has the advantages of environmental protection, high module consistency, low cost, and high quality, and is very advanced in China today. So what role does each factory play? BSL Huizhou Factory mainly produces lithium forklift battery, AGV lithium battery, Golf cart lithium battery, Lithium Solar Battery, and other products production. BSL Dongguan Factory, currently mainly produces Lithium RV battery, Lithium Marine battery, Lithium Floor Machines battery, and other products production. BSL Jiangxi Factory East mainly produces micro-grid energy storage batteries. This year many of our dealers will have the opportunity to visit our factories and get more closely connected with our team and resources. Will we see you in China this year? Our Strength BSL is an innovative company, and its strength is in design. BSL will regard the materialization, generalization, and modularization for each product at the beginning of the design process. The first one is the core parts; we must develop and produce independently. The second one is our important parts; our factory has the advantage of our own design, according to our require Module selection design and independent research and development of BMS. This gives full play to our capacity for independent innovation and also makes full use of the production advantages of our suppliers. Thirdly; our products are designed to be generalized and standardized, which greatly increases the number of batches of an overall product from the supplier, with our investment in molds, we will greatly reduce the cost. This is the advantage of our overall design and development. The future In the future, as our factory expands into a larger production scale and pursues a more complete industrial chain, the focus will be on progressively improving toward digital intelligence and mechanized production. We will improve production efficiency, ensure product quality, improve environmental requirements, ensure safe production, and allow our employees to work in a better environment. At the same time, through the perfect MES system of production control, we will be able to achieve faster conversion of sales orders and production orders, control all production processes, speed up delivery, and better serve the market.
CoEvolution’s multi-fleet orchestration solution improves warehouse efficiency by 30% for Fortune 500 retail giant
Smart logistics specialist CoEvolution has announced its revolutionary CO-PICK smart warehouse system delivered substantial increases in warehouse efficiency for South Korean multinational Lotte, raising throughput at the facility by 30% more SKUs per day. The AI-powered CO-PICK solution from CoEvolution used by Lotte has been tailored specifically to the customer’s needs, using a multi-vendor fleet of robots and orchestration software to deliver highly efficient picking, order fulfillment and integrated logistics support for 417 Lotte Super stores. Lotte Group is a Fortune 500 company and a leading retailer in South Korea, with a significant presence in retail, food, electronics, confectionary and other industries. Having considered and researched multiple options, it selected CoEvolution to work on a project to automate its entire warehouse transferring operations using a multi-vendor robot fleet. The challenge The wide variety of SKUs and high requirements for picking efficiency and accuracy within the retail industry places substantial pressure on warehouse operations. Lotte required a new system of warehouse automation to help ease pressures resulting from a rapid increase in the minimum wage in Korea. During a periodic review of its warehouse systems to see how the latest technology could deliver operational improvements, Lotte Global Logistics found isolated ‘islands of automation’, large amounts of manual work required for transfers, and unused vertical space within the warehouse that could be optimized for storage. Robots were identified as providing an opportunity for further productivity and efficiency. In order to ensure the warehouse system operated smoothly and at optimal levels of throughput, Lotte Global Logistics decided to look into a multi-fleet robot solution to carry out the range of tasks required. The solution Lotte Global Logistics considered multiple options from a range of different solutions providers and decided to adopt CoEvolution’s CO-PICK solution to accelerate its warehouse logistics operations. CoEvolution designed a custom multi-vendor robot fleet orchestration solution based on Lotte’s preferences to provide highly efficient goods delivery across 417 stores. The retailing warehouse project saw CoEvolution identify a range of solutions using different robot combinations that were then tested via its SIMULATOR product to ensure the best choice was made. For the Lotte solution, CoEvolution integrated the mobile robots with its robot control system (RCS) so they are able to operate as a single fleet. In this particular project, CoEvolution’s smart logistics control system docked with Lotte’s warehouse control system (WCS) to create a customized automated warehouse solution that provided full control and visibility of the new operation at Lotte’s warehouse. The solution involved a combination of high-tote robots used for efficient picking and latent autonomous mobile robots (AMRs), which were docked with the existing system, and equipment such as conveyors and robotic arms to facilitate smooth and efficient pallet transferring and order picking. CoEvolution’s CO-PICK smart warehouse solution utilizes different types of robots working collaboratively to deliver high throughput and high storage density, significantly reducing customers’ labor and storage costs in many different kinds of warehouses. The benefits As a direct result of the new automated warehouse solution connecting and accelerating order fulfillment, overall efficiency rates went up at the Lotte facility, with throughput raised by an additional 30% SKUs and storage capacity increased by 200%. In addition, a 20% release of manpower was achieved from heavy pallet transferring, which had previously all been handled manually (a crucial consideration in an era of ongoing labor shortages). Fast to deploy and easy to dock with Lotte’s system and existing automated equipment, the multi-fleet orchestration warehouse software from CoEvolution is simple to maintain and use. There is no complicated configuration required for setup, and little or no training is required for operators before they can start using it. The CoEvolution solution delivers highly efficient and accurate performance in Lotte’s warehouse, alongside improved use of space and secure data transfer. It has connected and automated the whole process, from issuing orders to implementation, with all the simplicity and ease of use of a fully integrated system. With the help of CoEvolution’s CO-PICK solution, Lotte Global Logistics was able to break the boundaries of the original independent islands of automation, scheduling robots to connect the whole transferring process and turning the warehouse into one open map. Commenting on the success of the retail warehousing automation project, Vice President of Lotte Institute of Logistics Technology Seungkee Baek, says, “We are delighted that we selected CoEvolution and CO-PICK to come on this automation journey with us. The new smart warehousing solution has increased our productivity and throughput, made optimal use of our warehouse space, and works seamlessly with our operators.” CoEvolution Co-Founder and COO Michael Wang add, “The best CO-PICK solution for Lotte combines high-tote robots and latent AMRs with the existing conveyors and robotic arms to deliver optimal efficient pallet transfer and order picking, connecting the whole logistics process. “With our Industry 4.0 CO-PICK solution it is possible to simulate and select the best multi-vendor robot fleet orchestration combination for your business and manage it through a single control system. Expected productivity gains are available within days, alongside the flexibility to scale at your pace. Automation doesn’t need to be complicated!” About Lotte Group Lotte Group is one of the top conglomerates in Korea with over $67B (USD) in global revenue. Lotte is engaged in diverse industries that include hotels, resorts, fast food, beverages, retail, financial services, heavy chemicals, electronics, IT, construction, publishing, confectionary products, and entertainment. To learn more, visit www.lotte.co.kr About CoEvolution CoEvolution is a leading solution provider of automation logistics. The company offers a unified robot control system that can orchestrate and optimize a mixed robot fleet’s task assignment, path planning, and traffic control, which gives customers the flexibility to choose the best combination of robots from multiple vendors. Current customer case studies can be viewed here. To learn more, visit www.coevolution.ai
Seven ways to get ROI from Robotics Integration in manufacturing
Technology is rapidly reshaping the way business is conducted, particularly for manufacturers. Robotics is poised to transform the entire manufacturing industry, and many business leaders are finding themselves faced with difficult decisions in regard to automation and robotics in their manufacturing facilities. At the core of these decisions is the calculation of what type of return on investment a robotic integration would provide. Here are seven factors to look at when evaluating potential ROI from the integration of robotics in your manufacturing facility. EFFICIENCY Efficiency is one of the most important measurables in business, and a robotic integration is likely to meet or exceed your expectations. Improved efficiency is often experienced in critical areas such as manufacturing processes, product throughput, uptime, and energy. RELIABILITY Reliability is an essential part of your production and planning process, and by choosing a robotic solution over fixed automation, your potential failures are minimal. The mean-time-between-failure of a FANUC robot, for example, is documented at 78,000 hours, depending on the model. UPTIME Uptime associated with a FANUC robotic turnkey system designed, built, and integrated by Wauseon Machine is very high when proper preventive maintenance practices are followed. FLEXIBILITY The flexibility of our turnkey systems allows you to not only reprogram your robot as required when processes change but also allows you to retool, redeploy, or redevelop your equipment in a more cost-effective manner than other fixed automation solutions. QUALITY Quality is built into every robotic system we deliver. Our vertical integration provides us with control over the design and build of a complete system, including components that are typically outsourced. Your project stays with us from start to finish. REPEATABILITY TOLERANCES Repeatability tolerances are unachievable by a human operator and can be reached with a robot. Companies that choose robotic automation may experience quality and employee safety improvements throughout the entire process flow. PRODUCTIVITY Productivity improvements will be witnessed quickly. Your downtime will decrease, throughput will increase, and total hours in production will be higher when compared to traditional human labor. About Wauseon Machine and Manufacturing Wauseon Machine and its sister company, McAlister Design & Automation, are industry providers in robotics automation, tube fabrication equipment, and build-to-print precision machine parts. With 40 years of experience, the company has four separate focus plants dedicated to Tube-Forming Technologies, Robotic Automation, and Precision Machining. Across their plants, they focus on tool development, machine building, automation, and providing contract CNC production machining of volume and custom precision piece parts and components for other companies. Wauseon Machine / MD&A are best-in-class suppliers of system integration to incorporate automation into a variety of industries, applications, and cutting-edge technologies for manufacturing.
How lithium-ion forklift batteries are a game-changer for the paper and packaging industry
Industry Challenge A typical paper roll may be loaded, transported, and unloaded 4-16 times on its way from the paper mill to the printing press. All stages of this transport chain require powerful, dedicated handling equipment to minimize downtime and operating costs. Newsprint, coated paper, craft, or linerboard – high-volume, uninterrupted processing of paper rolls, pulp, and waste bales requires powerful equipment. The power supply usually needs to be so rugged and reliable that you can run it non-stop. Until recently, Class I and II forklifts using tilt and swivel attachments were primarily powered by LPG internal combustion engines or lead-acid electric motors. Both have their own set of problems, but three main ones are common: run time, high energy costs, and pollution. The pulp and paper industry is an “edge” industry for Li-ion technology. Its material-handling needs range between those industries where electric forklifts have traditionally been available, such as small warehouses and supermarkets, and super-heavy industries, such as mining, where huge machinery consumes so much energy that conventional wisdom says it cannot be used converted into electricity. “We’re proving that’s not true,” said Haley Ning, director of marketing at BSLBATT. “The paper industry was one of the first heavy industries to adopt lithium-ion batteries, but others will follow.” Pulp and paper facilities are ready for conversion because they generally have access to electricity and stable infrastructure with a consistent grid; in contrast, many mining operations are located in undeveloped areas. “Our battery offers great potential for paper processing,” says Felix Du. “Furthermore, where hygienic handling is a mandatory requirement – such as paper converting and packaging, including food packaging – the absence of harmful fumes and low maintenance are important.” How BSL lithium-ion forklift batteries are changing the paper and packaging industry Case 1 A Taiwanese paper mill is retrofitting new lithium batteries with a Yale ERP45VM forklift. 4500KG. The Electric Buffer Tire Trucks are all 83.2V powered by a 1400Ah BSL Li-Ion battery. Six trucks carry the rolls to the loading and unloading warehouse, where they are stacked in warehouses for distribution. There are also two trucks for excursions with rolls that need to be rewound. All eight trucks run on one battery, which will last all day, with quick opportunity recharging sessions during breaks and lunches. Case 2 A large Israeli paper mill is using a Yale ERP55VM6F2170 to retrofit new lithium batteries to feed the production line. The end of the line is served by eight Yale ERP55VM6F2170 forklifts, which have all recently switched from lead-acid powered electric trucks to BSL lithium batteries. There are 5500 KG capacity trucks equipped with 2267KG paper roll clamps and BSL lithium batteries with 2200KG installed. 8 Yale ERP55VM6F2170 forklifts do very heavy duty – 3 shifts per day, averaging 4,800 hours per year! This is well beyond any industry standard rental (approximately 1500-2000 hours per year). Powerful, durable BSLBATT lithium batteries are the best choice when you need to maximize uptime and safely handle paper and pulp products. Also for pulp and paper manufacturers, sustainability is another factor. It was a “eureka moment” for Haley Ning to realize that many of his clients had internal mandates to reduce their factories’ carbon footprint. “Forklifts may not even be an area they’re thinking about helping achieve those goals,” he said. “Switching from lead-acid batteries to lithium means switching from dirty to clean energy. Efficiency is common in every industry. You’ll save money along the way on lead acid. In Israel, it can cost 5-10 times more to run a truck with a lead-acid battery, depending on where you live and work. Our experience is that we can help someone reduce their total cost of ownership by 25-30% over five years,” he added. Summarize BSLBATT is known for producing some of the most durable, reliable, safe, and trouble-free Li-ion batteries for applications where durability, speed, and energy efficiency directly impact the bottom line. BSLBATT lithium-ion batteries help reduce downtime by taking advantage of breaks to opportunistically recharge when operations are most convenient. Zero routine maintenance and energy efficiency provide quick cost savings. Lithium-ion technology is the best forklift battery to help the paper and packaging industry achieve warehouse and operational efficiencies. The benefits of using lithium-ion batteries can help achieve these operational efficiency goals. Fleet managers in the paper and packaging industry can improve operational efficiency by implementing lithium-ion batteries in their forklift fleets.
Learn the six most common myths about the Industrial Lithium-ion Battery
The global lithium-ion battery market size is projected to expand by over 18 percent between 2021 and 2030, compared to the projected 5 percent growth in the global lead-acid battery market size during that same time period. Lithium-ion batteries have multiple advantages that make them ideal for any operation. The battery's unique properties allow businesses to improve safety, and efficiencies, and significantly improve ROI. Lithium-ion batteries have multiple benefits over their IC and lead-acid counterparts, including faster recharge times, opportunity charging, long cycle life, and full cloud data reporting (BSL GPRS+GPS). Li-ion batteries virtually eliminate hazardous off-gassing and spills, making them safer and more eco-friendly than their competitors. We have examined and debunked the top lithium battery myths below to simplify the decision-making process. Myth 1: Battery-powered devices cannot withstand climate fluctuations To some, the idea that a battery can withstand a range of environmental conditions is unfathomable. For those who work in cold storage, the low-temperature freezer and refrigerator environment can put a lot of stress on lead-acid batteries, resulting in longer charging times and frequent interruptions to daily operations. They needed a lithium solution that could withstand the low-temperature factor, and lithium batteries have been proven to do this over the years, but it would be a mistake to underestimate that lithium batteries cannot be used at -25°. Batteries are increasingly being developed to withstand harsh environmental elements, greatly increasing the durability and durability required for these conditions. While extreme heat and cold, as well as strong vibrations and exposure to moisture, can damage a battery's charge, it does & #39;t prevent the battery from delivering optimal power performance. Enhanced testing capabilities for batteries allow manufacturers to expose batteries to harsh environments to ensure they will deliver effective and efficient performance no matter the weather. Tested at temperatures from as low as –25°C to as high as 60°C, the range in which BSLBATT batteries can deliver robust, consistent performance has increased. Myth 2: ALL Lithium-Ion Batteries Contain Cobalt Many people shy away from investing in Lithium-ion because of the ethical and environmental costs of mining cobalt. While many Lithium-ion batteries in everyday tech use cobalt, the truth is that not all Lithium-ion batteries are made with cobalt. In fact, the LFP (Lithium Iron Phosphate) battery chemistry is quickly surpassing NMC (Nickel Manganese Cobalt) in popularity and performance for industrial equipment. LFP batteries are Lithium-Ion batteries that do not contain cobalt. Aside from not containing cobalt, LFP batteries are better for our environment due to the fact that they are much less toxic, with iron and phosphate readily available. LFP is one of the safest and most reliable chemistry options out of all possible alternatives for lithium-ion batteries. This is why LFP batteries continue to grow as the preferred battery choice. Myth 3: Industrial Lithium-ion Battery Tech is “Too New” It is commonly assumed that lithium-ion technology is too new to be the superior choice over legacy internal combustion and lead acid battery systems. In reality, Lithium-ion technology has come leaps and bounds from where it first started in 1991 and is continuously improving at a rapid pace. The last decade has seen industrial lithium-ion begin to take over due to its reliability, low maintenance, and long cycle life. Today, lithium-ion batteries cost 97% less than they did when they first came to market and can now run for 8+ hours straight. When comparing lithium-ion batteries to their lead-acid counterpart, for example, lithium-ion is already the more economical, eco-friendly, and efficient option for users to choose from. Lithium-ion batteries bring new technology and capabilities that have not been seen in the market previously. Each year these batteries are on the market bringing new developments such as improved lithium cell performance, BMS capabilities, and durability among others. Lithium-ion is already established as a better alternative and continued improvement will prove lithium-ion batteries are the power source of choice for the future. MYTH 4: Battery power is unreliable As traditional fuel-powered machines are widely considered the norm, there is a tendency to dismiss battery power as it is unknown. Concerns remain over the impact, potential downtime can have on a business as they work out how to fix the issues that have occurred. However, modern Li-ion batteries are designed to help the user should something go wrong. Built into the battery is a battery management system (BMS) that offers a wealth of data and insights surrounding battery health and performance that keeps the battery, and in turn, the equipment, functioning at its best. Being able to monitor this data helps to prevent downtime as users can constantly measure the state of the battery. The BMS serves as an onboard computer that monitors and measures information such as the pack’s temperature, charge/discharge currents, and voltages of each cell bank. As the BMS constantly monitors the battery’s health, it is a great tool for supporting users should something go wrong. The battery can communicate with you to identify the issue so you can get back to work as quickly as possible helping to reduce downtime. BSLBATT Li-ion batteries also feature internal contactors, which means when the equipment is off, the battery is off, helping to protect those doing maintenance to the battery. MYTH 5: Lithium-Ion batteries aren’t recyclable Recycling batteries is often considered impossible due to the difficulties of disposing of older nickel-cadmium (Ni-Cd) batteries. These difficulties do not apply to Li-ion batteries that are in fact incredibly recyclable. Li-ion batteries often have a second life in them (roughly 80 percent of the battery capacity remains), allowing them to be repurposed for other applications at the end of their life cycle. Li-ion batteries do not contain the same heavy metals that used to be found in old batteries, which means that they can be safely recycled without fear of unwanted chemicals getting into your water supply. The bottom line Once the misconceptions around Li-ion batteries are removed, end users are left with a reliable, rugged, and sustainable power source that helps OEMs meet
BSLBATT lithium-ion batteries to ensure uninterrupted multi-shift warehouse forklift operations in cold temperatures
One of South Africa’s leading chocolate producers switched to BSLBATT lithium-ion batteries to ensure uninterrupted multi-shift warehouse forklift operations in temperatures ranging from -25℃ to 30℃. The company profiled here is one of the largest branded food companies in South Africa and has its own manufacturing plant in South Africa. In 2021, companies are looking for ways to improve operational efficiency and safety. Low-temperature freezer and refrigerator environments can put a lot of stress on lead-acid batteries, resulting in longer charging times and frequent interruptions to daily operations. The conversion to Jungheinrich trucks powered by Eternity Technologies South Africa, the exclusive distributor of BSLBATT lithium-ion batteries in South Africa, went smoothly and did not require any operational or infrastructure changes. As a result, operations management saw an increase in forklift operating time, a significant reduction in recharging time, and overall battery maintenance time. Workplace safety has also improved. This time we came to Ferrero’s chocolate factory to visit our customers and investigate the usage of our BSLBATT 51.2V 690Ah forklift battery after one year. The forklift used is a Jungheinrich forklift. The use environment is in cold storage at a low temperature of -25 ℃ to -30 ℃ degrees, and the forklift is replaced every 45 minutes. The battery is in excellent condition after a year of use! No fault codes whatsoever! No problems during use! More and more companies are looking to use the advantages of lithium-ion batteries in forklift trucks and warehouse equipment for their intralogistics processes. But is this also possible in a temperature-controlled environment, such as cold storage in arctic temperatures? How do lithium-ion batteries maintain performance in cold and fluctuating temperatures? Why use lithium batteries in cold storage? ● Batteries that retain capacity in cold warehouse temperatures (conventional lead-acid batteries can lose 30–50% of their capacity in cold conditions) ● Electrical equipment that is unaffected by condensation and humidity inside temperature-controlled facilities ● Top safety and hygiene standards ● Increased uptime, reduced costs, greater efficiency, and equipment utilization ● Data-driven management of material handling operations ● A greater share of clean power and overall reduction of energy use in order to meet corporate sustainability goals Why BSLBATT Lithium Forklift Battery? ● BSLBATT Low-temperature series lithium Batteries maintain 95% of their nominal capacity and demonstrate stable performance in a cooler or freezer at -25° to +30°C ● All BSLBATT Low-temperature series Lithium Batteries are sealed against condensation; all other battery series can be upgraded with a sealed package ● Li-ion batteries are a safe, non-toxic power source with zero emission of pollutants ● Single-battery operation through multiple shifts, zero daily maintenance, no battery room ● BSLBATT advanced BMS provides data on each lift truck battery charging event, energy throughput and much more ● Lithium batteries use up to 30% less electricity than lead-acid batteries due to better energy conversion ● Absolutely secure system with high availability If you want to know more about the maintenance and use of lithium batteries for forklift trucks, please subscribe to us!
How to select a Lithium-ion Battery Supplier: OEM eight questions to ask
Making the Decision: Lithium-Ion Battery Supplier The lithium-ion battery market is in a state of flux. Lithium-ion is a relatively new technology that has taken off in the last five to 10 years and demand for these batteries is high and growing. This has attracted many OEMs and created something of a buyer-beware market for OEMs. Many critical factors must be considered when deciding on a forklift battery supplier. Choosing the wrong lithium-ion battery for a forklift can impact the entire operation of an OEM’s business, from procurement to production. An OEM’s day-to-day operations depend on forklift transportation, and a forklift’s day-to-day operations rely heavily on the battery. Choosing a lithium-ion forklift battery supplier is the first step in determining the success of an OEM’s daily processes. OEMs need suppliers who can meet JIT shipping demands, lead technical innovation, and provide extended technical service. Without that, you may end up with a lithium-ion supplier instead of a lithium-ion partner who will be with you for the long run. That can lead to dissatisfied customers and lost time and money. Ask the manufacturers these questions: To get an idea of how established the company is ask how long they have been in business, how long they have been serving the material handling industry, and whether they have supplied batteries to major OEMs. You could also ask if they offer a full portfolio of batteries including flooded lead-acid, AGM, and lithium-ion. You may want to move on if the manufacturer is a start-up, has been serving the material handling industry for just a few years, or has not supplied batteries to OEMs. Older, more seasoned companies that understand the material handling industry and manufacture and sell a full line of forklift lithium battery products generally know the issues that can damage batteries and shorten their lifespans. They often engineer solutions to these problems in their products. How long have you been working with lithium-ion technology? Again, the company probably has a lot to learn if the answer is just a few years. What kind of customer support do you provide? Make sure the company has a U.S.-based and Europe customer support line staffed by real people who can answer questions and help your technicians troubleshoot issues. Ask if support is available 24/7 and if the staff includes representatives dedicated to lithium-ion products. Many newcomers to the market simply don’t have the infrastructure to provide that level of service. How do you support the dealers who carry your products? You don’t want to work with a supplier who sells products and then forgets about you. To avoid phone tags and long hold times, look for a manufacturer with a systematic approach to communicating with dealers. Ask if the manufacturer has an authorized dealer network through which it trains dealers to sell its products and provides them with the information and materials they need. How do you sell your batteries? Many battery manufacturers sell directly to dealerships and are unable to provide the follow-up services dealers may need. Look for a supplier who sells their batteries through a network of trained distributors. These distributors generally know and stand by their products, adding value to your purchase. How is your battery different from others in terms of design and engineering? Look for products with UL2580 certification and at least an IP67 rating. This helps protect the battery from damage from vibration, water, and dust and can extend its life. Make sure the battery is embedded and modular expandable. Ask how the battery is designed to move the damaging heat it generates away from the cells. Most manufacturers do this through inexpensive components called heat sinks because they are easy to make and add on. But heat sinks should not be the only method of heat management. Well-made batteries reduce the heat generated and allow for natural cooling in the design. This requires more engineering expertise, but it boosts efficiency, improves safety, and prolongs battery life. What range does your battery get? To help OEMs, BSLBATT has developed 43 standard modules for lithium batteries of different capacities, which can form parallel building blocks in forklift battery compartments. Up to 20 of these modules can be stacked in parallel, and the total capacity can be tailored to forklift OEM needs. It’s also worth mentioning that OEMs must check usable capacity, not advertised capacity. The stated capacity may be based on the sum of the individual cells within the battery, which does not take into account internal losses like usable capacity. Real-world test data and customer testimonials are the best way to understand the usable range of a battery. This is especially important in the high-capacity, high-current, and relatively low-voltage batteries used in MHE. What safety features are built into your battery? Look for a battery with lithium-iron-phosphate cells, one of the most stable lithium-ion battery chemistries. Make sure the BMS features several levels of safety redundancy. That way, if one level fails another will step in, catch the issue, and turn the battery off, protecting you and your property. Ask about UL certifications. Is the entire pack UL-certified or does the manufacturer rely solely on the cell provider’s UL listing? BSLBATT is the first forklift lithium battery in China to obtain UL2580 certification for its complete product line. Stocking batteries on pricing alone is a big mistake that can impact your bottom line. Be sure to compare the manufacturers’ experience, support services, and products. Investing a little time in your decision can have big payoffs in your sales, service, and customer satisfaction. BSLBATT -Your trust OEM Lithium-Ion Battery Supplier in China BSLBATT battery has owned 10 years of OEM battery pack experience for Material Handling, Paper, and Packaging, Food and Beverage, Refrigerated Storage, Manufacturing Industry, Fresh Produce, Wine Industry, Distribution, and 3PL industries applications. What makes the BSLBATT the Superior Lithium Battery for your Motive Power needs? The answer is quality at every step. The BSLBATT Battery has been validated to over 60 industry quality and safety checks. It has multiple layers of monitoring, safety, and backup redundancies
New generation of Signal Towers are brighter and simpler to order and maintain
Signal tower lights play a critical role in protecting the safety of people and equipment in manufacturing and process control environments, providing visual and audible indications of system status and alerts of dangerous conditions. They are relatively simple devices, but until recently, they have been notoriously difficult to configure, order and stock because of the proliferation of different sizes and options to meet the wide range of applications. Fortunately, a new generation of signal towers changes all this. New technology and new designs make state-of-the-art signal towers much brighter so that one size fits all applications and environments. Now, ordering signal towers is much easier and fewer spare parts are needed Typical Signal Tower Color Schemes Signal towers have been around for decades. They are also frequently called stack lights due to their vertical orientation. They contain up to five lights, of different colors, with each color signifying a particular status, warning, or alarm. Despite efforts to create international harmonized standards for indicator lights and their meanings (e.g., IEC 60204-1, Fifth edition Chap. 10.3.2), implementations vary. In general, the following conventions are commonly applied: RED is an alarm condition signifying an emergency or hazardous situation. AMBER warns of an abnormal condition or an impending critical situation. GREEN represents normal machine or process operation or a non-hazardous environment. BLUE signifies an important/mandatory action that is not urgent, such as refilling a hopper with raw material or scheduling a service call. WHITE does not have any universal designation. It is often used for productivity monitoring. Within each color category, the light can be continuous or it can blink intermittently to indicate a more urgent condition and to attract more attention. Likewise, stack lights frequently incorporate a sounder module for audible signals for more effective warning and alarming. Sounders can generate a variety of tones including simulated bells, continuous tones, and siren sounds. Wide Range of Applications Sometimes a stack tower will contain only two modules. For example, laser cutting machines may use a green light to indicate that the machine is on and everything is working properly, and a red light will flash when the laser is pointing downward in cutting mode to warn operators and to alert other workers to stay clear of the machine. In addition to warning indication and machine fault management, signal towers are also commonly used for productivity monitoring (rate-based machine output management with displays counting parts per hour or parts per shift), as well as equipment effectiveness and productivity (uptime and downtime). In fact, stack towers are often called andon lights, for the andon system of quality control that is a principal component of the Toyota Production System. It empowers workers to stop production when a defect is found and immediately call for help. In the andon system, a green light indicates that production is proceeding normally. Yellow signifies that a problem has appeared and the operator needs assistance, and red alerts supervisors that the problem needs further investigation. Stack lights are widely used as warnings and alarms to protect workers, equipment and buildings from elevated levels of hazardous chemicals. For example, green lights may signify very low levels. A yellow light with an audible signal would designate detection of say, five parts per million of ammonia gas. And flashing red, with a strobe light and a loud audible alarm would be triggered at more dangerous levels. New Generation of Stack Lights A new generation of stack lights incorporates LED elements to replace incandescent bulbs. The LEDs, which can be 10,000% brighter, have a number of important advantages. First is the obvious benefit that because they are brighter, they are much more effective in performing their function of being clearly visible and capturing attention in all ambient light conditions, including outdoor installations. High luminosity is also increasingly critical indoors. Industrial spaces are being equipped with better artificial lighting and more natural lighting is being used for energy saving and sustainability. A second benefit is that LEDs last much longer than incandescent bulbs. Whereas incandescent bulbs typically are rated at a lamp life of only 2500 hours under ideal conditions, LED elements last for at least 50,000 hours. Moreover, LEDs are not vulnerable to vibration and shock the way incandescent bulbs are. Third, LED bulbs generate less heat and consume much less electrical power. The Size Advantage All of these benefits are important, but they are commonplace for many other applications where LEDs have replaced incandescent bulbs. Perhaps the most significant advantage of the new generation of stack lights comes from the much smaller size of the LED elements compared to incandescent bulbs. One of the problems with incandescent bulbs is they need to dissipate heat, and therefore to produce more luminosity, you need a larger bulb, which in turn is encased in a larger colored lens. As a result, stack towers varied in diameter up to 4 inches (100 mm). State-of-the-art LED stack towers have lenses that are about half the diameter even though the systems are much brighter. One-Size-Fits-All for Easier Ordering and Inventory Catalogs for signal towers with incandescent bulbs can run 100 pages or more, with varying bulb and lens sizes needed depending on the luminosity requirements for each application and environment. Selecting the right size and figuring out all the parts required has complicated the ordering process. And if a facility requires a variety of sizes, maintaining an inventory of all of the different spare parts gets to be costly and burdensome. The new state-of-the-art LED signal towers are bright enough so that one-size-fits-all, or nearly all, applications. It’s now much simpler to figure out what is needed for each application, and maintaining inventory is much cheaper and easier. Signaling towers are a simple and effective solution for a wide variety of applications. Now they are as easy to order, install and maintain as they should be.
Protecting workers without sacrificing productivity
Innovations in material handling: Working smarter, not harder Manufacturing facilities and distribution centers traditionally had to choose between keeping their workers safe or keeping them productive. Thanks to recent material handling innovations, companies no longer have to make that trade-off. Innovative and affordable material handling solutions empower workers to perform tasks faster and with more precision, while also reducing the risks of injuries from accidents and repetitive motion, and lowering the costs associated with damaged parts, products and machinery. The combination of increased productivity, fewer injuries, and fewer damaged parts and machines directly increases profit margins. The Push for Higher Productivity High productivity has always been crucial to being profitable and remaining competitive, and it has become even more important during this period of acute labor shortages in the manufacturing and logistics sectors of the economy. In fact, the National Association of Manufacturers Outlook Survey finds that “attracting and retaining a quality workforce” is one of the top business challenges among respondents and predicts that US manufacturing will have 2.1 million unfilled jobs by 2030. Instawork reports that 73% of warehouse operators can’t find enough labor. As companies struggle to recruit and retain workers, the reduced workforce is pressed to be more and more productive. The potential problems with this trend are obvious. “Beyond causing stress, the lack of skilled workers has heightened workplace injury, product liability, and property damage risk for these businesses,” warns Liberty Mutual Insurance. Accelerating Trend to Automate Businesses have increasingly turned to automation to address these challenges. Automation can reduce labor requirements, with fewer employees needed to perform the same functions, and it can also help with recruitment and retention by making jobs more appealing to workers. However, full automation is not appropriate, or even possible, for every task, and it often does not make business sense. Automation systems are expensive to design, fabricate and install and often require specialized skills to operate and maintain. For many manufacturing and logistics applications, highly automated systems, including robotics, are simply not suitable because they are less flexible than humans, the most versatile machine of all. Worker Assistance Solutions Fortunately, a number of material handling solutions exist between fully manual processes at one end of the spectrum and completely robotic automation systems at the other end. These solutions utilize innovative system designs and proven technology to assist workers in performing their jobs better and faster, while also reducing strain and injuries and limiting damage to parts and equipment. These worker assistance solutions combine: the strength and power of a machine, with the control and cognitive thinking of a human. The basic concepts of mechanical advantage have been known for thousands of years. Understanding the power of the lever and fulcrum, Archimedes is said to have playfully boasted, “give me a place to stand and I will move the world.” Wheels, pulleys, wedges, screws, and other simple machines were put to use to dramatically expand what people could accomplish with much less effort. Intelligent Lift Assist Solutions: Work Smarter, not Harder Today, material-handling-assistance solutions fulfill the same basic promise, empowering operators to naturally and almost effortlessly lift and maneuver heavy, large, and unwieldy objects, as if the devices were an extension of their arms. Intelligent Lift Assist Devices (ILD) incorporate advanced technology, such as hoist systems with processor-controlled servo drives, to replace back-breaking work with fingertip control and maneuverability. But intelligent material handling solutions are not just about advanced technology. They consist of the smart overall design of complete solutions that utilize cranes and conveyors to best assist workers in each particular material-handling application on the shop floor and at the loading dock. Intelligent Devices The Gorbel G-Force® Intelligent Lifting Device exemplifies how state-of-the-art technology can effectively enable ergonomic and user-friendly load manipulation. The industrial processor-controlled servo drive system allows the G-Force to deliver both unmatched lifting precision and speed, a combination that traditional lifting devices have been unable to offer. In a study conducted by the Rochester Institute of Technology, workers in high-cycle settings were nearly 70% more productive using this system, compared to other lifting solutions, including manual lifting, chain hoists, and air balancers. The G-Force also excels at giving operators the precise control they need to carefully finesse expensive or fragile parts into place. During precision placement tests, the RIT study found that operators were 77% more efficient than with air balancers, and 59% more efficient than with traditional hoists. The high-speed servo control system and sensor technology, along with the highly-usable design, make the system remarkably easy, effortless, and natural to operate. Optional force sensing handles automatically detect force applied without requiring any handle motion, unlike other hoist systems that require operators to press a button or squeeze a handle to initiate upward or downward motion. Float Mode enables operators to precisely orient loads throughout the full stroke range by manipulating the load with their hands and applying as little as 1/2lb (227 g) of force on the load itself to activate the vertical movement. A combined collector/air swivel allows the handle to continuously rotate without damaging electrical conductors in the coil cord or optional air coil. This is ideal in applications where the operator is continuously rotating the handle. The control handles have operator-present sensing functionality, making them safe and intuitive, without the operator needing to depress a physical lever. Smart System Design of Workstation Cranes An optimal material-handling solution pairs the intelligent lifting device with a crane system that makes a horizontal movement as easy and efficient as vertical lifting. Workstation cranes achieve this goal better than alternative solutions, with superior maneuverability, enhanced safety, and large rectangular area of unobstructed coverage. Workstation cranes also called overhead traveling cranes and bridge cranes, are a type of overhead industrial crane that consist of a moving bridge that runs across parallel runways. A lifting device travels back and forth across the bridge, while the movement of the bridge enables simultaneous movement in a perpendicular direction. A well-designed system will offer little rolling resistance to the bridge and trolleys