Advances in Smart Technologies for Material Handling
Advanced connectivity and data analytics enable manufacturers to optimize operations. This feature originally appeared in the March edition of AUTOMATION 2024: IIoT and Digital Transformation. The article discusses the increasing trend of smart technologies in the material handling and intralogistics industries, driven by sustainability, automation, and innovation. The article suggests that a warehouse distribution center in North Carolina saved more than $90,000 in one year after integrating the Regal Rexnord ModSort Divert and Transfer Module into its package handling process. The ModSort was designed to be run-on-demand technology on only 24 Vdc. Conveyor speeds increased from 50 to 90 ft/min, and annual labor costs dropped by $91,000. The author also notes that smart technology can enhance worker safety and sustainability, while maintenance and downtime decrease. As the industry continues to evolve, it is critical to engineers to stay up to date on the latest technologies.
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Inside a large distribution warehouse in Charlotte, N.C., a team of workers faced a daunting challenge: Manually handling incoming package types ranging from boxes to polybags while managing other business. The polybags were placed into totes, which helped ensure proper package conveyance. However, the totes also increased manual labor and the time it took to sort bags. The team spent 80 hours per week manually grabbing and pulling totes at a labor rate of $21.50. Was there any kind of smart technology that could help?
The material handling and intralogistics industries are driven by sustainability, automation, and innovation. In baggage handling, postal and parcel centers, and warehouses and distribution centers, revenue is determined by the performance of downstream industries and markets that bolster industry demand. Margins are thin, which is why so many facilities are excited by digital transformation.
Manufacturing industries are experiencing a significant shift toward investing in the Industrial Internet of Things (IIoT) and smart technology. With advanced connectivity and data analytics capabilities, manufacturers are leveraging smart technology to optimize operations, decrease downtime, and prolong the lifespan of mission-critical equipment.
The solution to the distribution warehouse’s material-handling challenges was the low maintenance ModSort Divert and Transfer Module from Regal Rexnord, which was installed in the facility to assist the workers by conveying polybags without totes (Figure 1). Quiet, safe, and low maintenance, the ModSort offers run-on-demand technology on only 24 Vdc. The ModSort module integrated into the warehouse’s package handling process. Conveyor speeds increased from 50 to 90 ft/min. Annual labor costs dropped by $90,000. This is a true story, and it’s one Regal Rexnord is proud to tell.
Figure 1: A warehouse distribution center in North Carolina saved more than $90,000 in one year after integrating the Regal Rexnord ModSort Divert and Transfer Module.
How does ModSort work? The idea for ModSort started in 2015 with a blue System Plast belt with embedded rollers. Original equipment manufacturers (OEMs) were excited by the technology but needed help developing it to meet their system needs. ModSort evolved to include a belt and motorized drive rollers (MDRs). ModSort now comes in many sizes and can include Perceptiv IIoT sensors, motors, bearings, and gearing. It has flexibility to meet the demands of various applications.
In addition to end-to-end powertrain solutions such as ModSort, Regal Rexnord is offers Perceptiv Intelligent Reliability Solutions, an interconnected matrix of sensors, gateways, and data, which empowers manufacturers to monitor products in real time and make data-backed decisions.
Change is hard. There is always an upfront cost; sensors to monitor brake oil levels or coupling vibration are not free. A custom engineered ModSort sortation system takes time and money to develop. However, the return on investment, coupled with increased productivity, sustainability, and decreased downtime proves the value.
When it comes to conveying and sorting, older technologies are not as efficient as newer options in the marketplace. Many have old-style pusher arms that are very loud and run by pneumatics. Those require frequent maintenance and adjustments to make them functional. On the other hand, ModSort is designed from the ground up to be a maintenance-friendly product. It’s easy to take apart and put back together, and if there is a problem it doesn’t take much time to figure out what that is. ModSort takes no compressed air and runs on 24 Vdc. It is quiet, approachable and safe.
ModSort is just one example, but like many smart technologies, its benefits are far greater than economic. Worker safety and sustainability increase while maintenance and downtime decrease.
While the industry has advanced considerably in recent years, its digital transformation is far from over. As artificial intelligence (AI) and language learning networks continue to evolve, manufacturing technologies will as well. It is critical that engineers, integrators, equipment manufacturers, and end users stay up to date on the latest developments.
Looking ahead to near future technologies, automated guided vehicles (AGVs) will minimize energy consumption and optimize production output by combining the ModSort system with Kollmorgen technology (Figure 2).
Smart systems that are IIoT-enabled are backed by decades of application knowledge and engineering expertise. Not only are the products reliable; engineers are often a phone call away.
This feature originally appeared in the March edition of AUTOMATION 2024: IIoT and Digital Transformation.