Advances in Smart Technologies for Material Handling

Summary

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.

Material handling solution 

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. 

Smart technology boosts sustainability, worker safety  

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. 

Looking ahead 

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).