palletcentral

PalletCentral • March-April 2021 33 straightforward under NIST standards. However, it is far too easy for an Environment, Health & Safety (EHS) manager to miss the implications of the rapid changes underway with Industry 4.0 applications with these siloed disciplines. As one of the first companies to implement dynamic robot control using sensor information and artificial intelligence algorithms, Universal Logic are experts in AI-based software control, system integration, and cloud based data solutions. e company has seen firsthand what is required to safely implement cyber-physical technology into traditional supply chain solutions. eir proprietary software, called Neocortex, spawned a revolution in AI/sensor/machine control, giving robots the "brain" to automate dynamic supply chain practices at high speed. Customer Problem Universal was contracted by a major grocer to automate sorting of pallets, accumulating daily from their various suppliers, at a rate of up to 400 pallets an hour with accuracy up to 99%. e pallets were of every type: CHEP, PICO, plastic and white wood. eir condition was infinitely variable – clean, damaged, debris, wet, tangled with plastic wrap and slip sheets. e traditional solution was to employ a team of forklift drivers, over multiple shifts, to gather random stacks of pallets from all over the warehouse, or inbound trailer loads. ey moved them into a staging area, sorted into homogeneous stacks, then moved them to a shipping dock for loading into outbound trailers. is proved to be an expensive use of labor, equipment, and floor space to execute. e speed with which the operator needed to function further increased the risk of pallet and machine damage, as well as worker injury due to continuous twisting in the seat to maneuver in reverse. In analyzing the solution, Universal's AI, software, and integration teams worked closely to deconstruct the problem, and build a system design solving the issues, including: work cell foot print, reduction in labor costs, reduction in forklift use as well as wear and tear, improved work safety, and capturing data metrics for inventory and quality control. Neocortex technology Universal spent a decade developing Neocortex – a true cyber-physical Industry 4.0 invention. It is a machine agnostic software "brain" for robots that uses sensor date, artificial intelligence, and machine control to provide real-time dynamic behavior at high speeds. e technology allows robots to replicate the actions of labor on supply chains in both manufacturing and retail. It is machine agnostic, working with all major brands of equipment. Neocortex is part of the enterprise software stack in a budding field known as the Internet of Robotic ings. Neocortex spans the network, residing at the edge, tethered directly to the robot controller and the PLC, in the onsite server room, and in the cloud. Universal's Turnkey Solution Universal designed the complete software/ hardware solution, integrating Neocortex with the robot controller, sensors, PLC, conveyors and safety systems. Handling 60-pound pallets at high speed requires a large industrial robot. In this case a 160KG Yaskawa Motoman. e solution must include safety barriers and light curtains to insure no person is near the robot while it is running. Additionally, with forklift traffic feeding pallet stacks into and out of the sorter, bollard and guardrails must be included to protect the equipment. Safety protocols are dictated by strict RIA and OSHA standards for industrial robot implementation and operation. Implementing robotic technology into a facility for the first time, requires careful training of operators and EHS managers. is is part of Universal's deliverable. It is far too easy to become captivated by the awesome power and capability of the robot, and simply think that you bolt it to the floor and turn it on. It is imperative that strict operating protocols be established and maintained. is is particularly important when an operator needs to override the system and enter the work cell. Safety managers need The integration of traditional automation with artificial intelligence software demands a wholistic approach to safety for a successful delivery. Robots have expanded their utility thanks to their general purpose design and seamless integration with sensor-based AI control.

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