Micro and Servomotors Boost Automation in Logistics

Faulhaber’s motors are used in virtually every area of the logistics chain. Drives and micromotors from Faulhaber can meet all the typical requirements – maximum power, speed, and precision with minimum volume and weight – of these applications. Brushless DC-servomotors and DC micromotors and only a few examples.

Global goods cycle is a challenge for everyone involved. The answer cannot be but extensive automation within the logistics chain, which would be unthinkable without a huge quantity of high-performance micromotors. These motors often need to generate considerable forces under extremely confined conditions and, above all, must always work reliably in continuous operation. This is why drives from FAULHABER can frequently be found in these challenging applications. The transmission of information has always been key to logistics. Nowadays, electromagnetic waves that are propagated through the ether and along cables perform this task much more quickly than in the past. The largest data volumes are transmitted using fibre optic cables. They form the backbone of the global logistics network: The cables pass on the necessary information by means of light signals – from the online order, through shared just-in-time production in smart factories to express doorstep delivery.

Connections with nanometre precision

Two fibre optic cables must be joined together fibre for fibre. This is extremely delicate work because each individual optical fibre is as thin as a human hair. The optical core is even thinner and has a diameter of just five microns. When two such optical fibres are joined together, the two ends must line up precisely with each other so that the signal can then later be transmitted cleanly without impairment. On construction sites, the precise alignment is carried out by small mobile machines. The individual fibre ends are first cut to length with anexact 90 degree cut, the protective insulation is stripped away and the fibres are then placed in the device. The device automatically and accurately aligns the two pieces with each other in three dimensions so that the flat ends meet precisely. They are welded together and then insulated again. Connection of the fibres and unimpeded flow of the signals are now guaranteed. The nanometre-precise alignment is performed by means of positioning drives from FAULHABER, e.g. with DC-micromotors of the 1524…SR series, with gearhead and lead screw as well as a high-resolution encoder. Drives that work with high-precision stepper motors are also used here.

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High degree of automation in warehouse systems

Thanks to this technology, the fibre optics can transmit the signals for a digital order over long distances without errors and at the speed of light. Orders can be sent by an end customer to an online shop, but just as easily by a production plant to a supplier. In both cases, a whole series of processes are set in motion. Ultimately, these processes result in products being retrieved from a storage facility and made ready for shipping.
Today, an increasing number of work steps involved in storing items in warehouses as well as retrieving these items and preparing them for dispatch are being taken over by automatic storage and retrieval machines, driverless transport systems and intelligent logistics robots. The computer-controlled machines receive a work order and then move automatically to the target rack space in order to deposit or collect an item there.
To enable this, they are – depending on the type of rack system – equipped with lifting columns, telescopic arms or grippers which grip and move the packages or trays. On board these automatic devices, there normally is not much space for the motors that are needed to drive them. The motors are frequently installed directly in the handling elements. There, despite their delicate proportions, the motors often have to lift considerable weights. Speed also plays a role: In the huge storage facilities of e-commerce companies, many thousands of orders are processed every day. Therefore, the individual steps must be performed rapidly.

Precise positioning, power and speed

A typical unit comprising a lifting column and gripper used on a robot contains a drive unit consisting of brushless DC-servomotors of the BX4 series with Motion Controller and planetary gearhead from FAULHABER. When used in the lifting column, for example, this combination ensures precise positioning, exact retrieval and reliable processes during continuous operation with constant load changes. The automated processes are monitored to some extend by camera systems. FAULHABER motors are again frequently used to drive high-quality, moving cameras.
After retrieval, the item is usually deposited on a conveyor belt or roller conveyor. These generally have track switches, paddles or pushers to separate individual packages or elements and to move them onto the desired processing path. In large warehouses in which thousands of packages per hour are transported on such conveyor systems, the speed of the automatic sorting systems is a key factor. The track switches must be moved to exactly the right position in a fraction of a second. DC-micromotors of the 2237…CXR and 2342…CR series in combination with a gearhead are frequently used for this task. Transport tasks are also often performed by automated guided vehicles (AGV). These vehicles are equipped with mounted modules for handling their cargo: Moving levers, clamps and pins ensure that the items are fixed securely while they are being transported. The moving elements each are equipped with a drive.

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Made-to-measure shipping boxes make packaging more economical

The items are transported to the packing station where they are packed in a made-to-measure shipping box. Automated packing stations use sensors to detect the dimensions of the item to be shipped and fold an appropriately sized box from a cardboard sheet. This not only saves material, but also shipping costs because the logistics service providers set their prices according to volume as well as weight. The actual folding work is performed by small levers and paddles in the packaging machine. Servo drives with integrated Motion Controller from FAULHABER are optimally suited for moving these elements. If packages are stacked on pallets for shipment, they need to be fixed securely in place. Straps made of fibre-reinforced plastic are usually used for this. They are attached using so-called strapping tools. These tools tension and weld the strap so that it is tight against the stack and holds it securely. Individual packages can also be additionally stabilized in this way. As the tools are handheld, weight is a particularly important factor – every gram saved helps protect the health of employees. For this reason, the motors used for tensioning need to be as small as possible, for instance the 3274 …BP4 brushless DC-servomotor. It weighs just 320 g, but can achieve a peak torque of over 1 Nm, which ensures that even heavy loads are secured safely.