October 11, 2023

Everything You Need to Know About Rust at arculus (And Beyond)

Even non-techies have probably heard of popular programming languages like Java, C++ or Python. However, a new language has been stirring the programming world in recent years. And it might well be on its way to becoming as mainstream as its counterparts: Rust. In this blog post, software developer Andy Brinkmeyer sheds some light on Rust’s benefits, technicalities, and recent implementation in the arculus tech stack.

A Brief Story of Rust

A programmer gets frustrated with a piece of tech. They get home, sit on their computer and try to solve it. This is the origin and story of several software projects and it’s no different with Rust.

Night scene showing a developer sitting in front of a laptop. Only his torso is visible. He is wearing a dark blue shirt and sitting to the right of the image. His hands are illuminated by the light coming from the laptop.
Several software projects begin with developers trying to solve personal frustrations

In 2006, Graydon Hoare, a Mozilla programmer, was forced to take the stairs to his 21st-floor Vancouver apartment after the elevator software crashed. He knew that such crashes are often caused by software written in C++ or C, which make it easier to introduce memory bugs. And so when Hoare finally got to his apartment, he opened his laptop and began designing a new programming language that would make it possible to write efficient code with improved memory safety. And the story of Rust began.

Seventeen years later, Rust has become one of the most popular languages on the planet. There are 2.8 million Rust developers around the globe, and the programming question-answer website Stack Overflow elected Rust as the most loved language for seven years in a row. Its economic relevance also can’t be questioned. Companies like Microsoft, Amazon, Meta, Discord, and Dropbox have openly talked about how Rust helped improve their system’s performance. And arculus is proud to join the group.

fn main() {
    println!("Hello, world!");
}

Example of "Hello, world!" code in Rust

What makes Rust so popular?

The short answer is that Rust addresses common pain points present in other languages while minimising any downsides. For that, it counts on a few main advantages, namely:

  • memory safety
  • security
  • strong community
  • faster development

Here is a closer look at what each of them means:

Memory Safety

This feature refers to Rust’s ability to pre-emptively avoid memory-related errors. They often lead to crashes, vulnerabilities, and unstable software behaviour. Unlike C and C++, where manual memory management can cause issues like buffer overflows and null pointer dereferences, Rust relies on three key concepts to ensure memory safety:

  1. Ownership: Each value has a single owner, making it explicit who is responsible for managing the underlying memory.
  2. Borrowing: Values can be accessed through references without owning them, which is called borrowing. Strict rules are applied here to ensure memory safety.
  3. Lifetimes: Ensure that references are not used after the data they point to has been deallocated, preventing references to invalid memory.

As arculus developer Andy Brinkmeyer explains, the Rust compiler enforces these rules at compile time. “This prevents most memory-related bugs, which is great”, he explains. The result is more robust and safe software. That's because in other languages, programmers need to manually ensure compliance with memory safety rules.

Security

Due to memory safety issues being responsible for a major portion of reported vulnerabilities in systems, Rust's ability to eliminate these issues significantly increases cyber security.

Strong community

Rust takes pride in having a “community-driven development process where most decisions are made through open discussion and consensus”. The “Rustaceans”, as the active members of the community like to call themselves, constantly create new documentation, resources and even libraries. This makes the experience of Rust fully collaborative and interactive for developers of all levels.

A photo of four developers at the arculus office. They are all talking to each other while working, and appear happy.
The Rust community is also growing inside arculus

Faster development

Rust enables faster programming through its combination of memory-safety and expressive syntax. By catching many common coding errors at compile time, the language reduces debugging time, ultimately accelerating the development cycle.

Rust core features

Andy explains that Rust shares many similarities with C++ since both are "statically typed, compiled languages without a garbage collector". Nonetheless, Rust's popularity comes from some of its unique features. Here is an overview of some of the most prominent ones:

Zero-cost abstractions

As Andy explains, “Abstracting away complicated logic and behaviour is one of the ways we make our software usable. Rust has this guarantee that abstracting away all this complicated logic for data types, does not incur extra cost on your compiled program”. In other words, zero-cost abstractions ensure that using convenient and expressive programming constructs, such as iterators, does not result in slower or less efficient code.

Concurrency and parallelism

Managing tasks simultaneously (concurrency) and utilising multiple processors to speed these tasks up (parallelism) are crucial aspects of modern programming. Still, handling them can be complicated and error-prone. Rust, however, makes both processes easier and more manageable. It does this by ensuring that when multiple tasks work with the same data, they can't inadvertently interfere with each other.

Andy explains that Rust makes working with concurrent and parallel code safer, through its ownership and type system. “Since a value can only have a single owner, it is impossible for two threads to own it at the same time. The type system complements this by marking if types are safe to share between threads, through borrowing and safe to send between threads by transferring ownership”, he elaborates. In other words, Rust prevents many concurrency and parallelism errors at compile time, using the same mechanisms it uses for memory safety.

use std::thread;
fn main() {
let v = vec![1, 2, 3];
let handle = thread::spawn(move || {
println!("Here's a vector: {:?}", v);
});
handle.join().unwrap();
}

Code snippet showcasing how to move ownership into a new thread. Source: Rust book

Pattern matching

Pattern matching is a technique used to compare data structures against predefined templates and execute specific code based on the matched pattern. It simplifies decision-making by allowing developers to handle different conditions in a structured and expressive manner. Patterns can be as simple as matching specific values. Or as complex as matching the structure of data types like enums or structs.

What sets Rust apart in this regard is its commitment to code safety. Its strong type system ensures that pattern matching covers all possible cases and reduces the risk of runtime errors. Rust’s concise and expressive syntax makes code more readable. It also provides features like pattern destructuring, automatic variable referencing, and customisation options.

Cargo

Cargo is Rust’s build system and package manager. What makes it a notable aspect of Rust is its capacity to handle many tasks. Some examples are building code, downloading the libraries on which the code is dependent, and building such libraries – also called dependencies.

“With Cargo, a Rust project centres around a single configuration file, where you define the properties like name, version, and dependencies. Cargo then handles the essential tasks, like setting up the project, compiling code, and linking build artefacts. In practice, using Cargo often boils down to running a single command like 'cargo run,' which simplifies the entire development process."

Andy Brinkmeyer
Two developers sitting next to each other at the arculus offce. They are both looking at their computer screens.
Andy (in the background) working on development tasks at our Munich office

Rust at arculus

The Rust programming language has proven to be a highly versatile tool, with widespread applications across various fields. The most prominent ones include Operating Systems (OS), Kernel programming, embedded systems, and cloud infrastructure. And while its numerous advantages make the number of potential Rust applications grow steadily, there is one field in which it still falls short: robotics.

“In robotics, tasks such as perception, path planning, and localisation involve complex algorithms. These algorithms have evolved over a long time through collaboration between academia and industry, and they are typically implemented in libraries”, clarifies Andy. “Many of these essential libraries are intertwined with C++, creating a dependency ecosystem that reinforces its use. Transitioning from this well-established field, where everything you need is in a single language, to Rust can be a significant step. While Rust is gaining traction in robotics, C++ still holds the number one position in this field for now", he concludes.

So why do we use Rust at arculus?

While using Rust in our robots is challenging right now, the language is the perfect alternative component of the tech stack that makes up our fleet software solution. “We need something with high performance that can manage multiple robots simultaneously. But we also need reliability and safety because the customers depend on us not crashing and not having errors in the code. They rely on us for the system to run indefinitely without problems. And that's why we are slowly implementing Rust”, highlights Andy.

Managing the transition

For Andy, what defines the approach to the transition process at arculus is “learning by doing”:

“Of course, people had time to prepare and study the (Rust) documentation. But we at arculus are really hands-on, in quite a literal sense – hands on the project, hands on the work. And in my opinion, contributing very early in the adapting phase to the codebase was the best way to get people up to speed. This approach combined with regular feedback by experienced Rust developers allowed us to quickly adopt it as a language and get everyone all set.”

Andy Brinkmeyer
Two engineers looking at the same computer screen. Behind them, a few arculees can be seen.
arculus developers like Andy (right) and Dennis (left), take pride in their hands-on approach

Learning resources

With such an engaged and supportive community, Rust is arguably one of the most well-documented programming languages – and that includes learning resources. For Andy, the most useful ones can be found on the official Rust project website. “The official Rust book was for me, the perfect mix between theory and real-world examples. But I also learned a lot through the other resources on the website, like Rust by example”, he concludes.

exit()

To sum up, Rust has emerged as a robust and adaptable programming language that is gaining recognition across various industries. Its origins trace back to addressing the need for safer and more efficient software, a mission it continues to excel at. From memory safety to security, a reliable community, and enhanced development speed, the language offers a compelling package for software developers.

As the arculus team integrates Rust into the tech stack, it leverages the language's exceptional qualities to ensure high performance, reliability, and safety in our software solutions. While the transition is ongoing, we are committed to the "learn by doing" approach, harnessing the wealth of resources the Rust community provides. Rust's journey at arculus reflects its evolution as a language that meets and exceeds modern software development's demands.

September 18, 2023

The arculee’s RCU®: Unveiling the Heart of Our Autonomous Robot

At the core of every robot are electronics components that drive its functionality. In the case of the arculee, the most significant of these elements is the RCU® - one central Robot Control Unit. This blog post delves into the electronic heart of our robot, providing insights from engineer Tobias Schwering. We’ll uncover the RCU®’s integral role in coordinating and enhancing the robot's performance, while discussing the challenges involved in its in-house development and production.

A first look inside the RCU®

The RCU®, short for Robot Control Unit, is the central electronic control module of our Autonomous Mobile Robot (AMR), the arculee. It integrates most of the robot’s functions onto a single self-developed Printed Circuit Board (PCB). arculus’ Senior Electronics Developer, Tobias Schwering, explains that this unit can roughly be divided into five parts:

  • Power distribution system: connects two 48V batteries to power consumers (such as motors and lifts), generates different voltages (e.g., 24V, 12V, 5V) for various functions, and manages the robot’s on and off procedures;
  • Central Computing System: runs the robot’s higher-level software (or "brain") on an embedded Linux module (Nvidia TX2) and provides communication interfaces such as Ethernet and USB ports, as well as a certified WiFi bridge and a 5G mobile modem for connecting to the customer’s network;
  • Three Inverter Modules: self-designed inverters capable of delivering 70A of current, enabling the arculee to perform heavy lifting tasks.

Taking it to heart

In many ways, the RCU® serves as a central hub for the arculee, almost as a “heart”. Firstly, it is the core power distributor within the robot, supplying electricity to all its subsystems. Additionally, it serves as a communication hub, collecting sensor information and processing it within the embedded Linux module. This data is then transmitted to the fleet management software, enabling the generation of precise instructions for the robots.

Keeping it in the family

As with most of the arculee’s inner parts, the RCU® was entirely developed and designed in-house. But Tobias explains that this wasn’t the original idea: “We were planning to have an external company working on it. But we soon realised that the complexity of the system was too high. It was also too entwined with the rest of the robot for such a combination to work properly. So, we brought the design in-house and have never regretted it.”

Tobias working at a desk in front of a window. There are two computers on the desk, one laptop and one monitor. To his left is the RCU®.
Tobias Schwering working on the RCU®

Full control over the RCU®'s design allows the team to directly tailor the arculee's electronics to different customer needs and easily implement new functionalities. The tailored inverter hardware and software design also vastly improved the performance of the robot’s driving system, as it allowed for increased power.

“To develop the RCU® internally, we need a deep understanding of all its subsystems, which enables us to fully optimise all of them to our use cases. And the learning never stops, so each version of the RCU® has substantial improvements over the last one and enables additional use cases.”

Tobias Schwering, Senior Electronics Developer

The RCU® development process

Developing exceptional robots requires continuous refinement. With the RCU®, it’s no different. “Many times we realised that the assumptions we made in advance and that drove the design, didn't fully meet reality. And new requirements appeared during the development process. So, we constantly needed to adapt and adjust the design accordingly.”, explains Tobias.

In other words, with each iteration cycle, the team draws from accumulated knowledge to make necessary adjustments. This involves streamlining the design by removing unused interfaces and systems, creating room for innovative functionalities that enhance the RCU. Along these lines, established performance metrics were also constantly reassessed and refined, ensuring that tasks were clear and well prioritised within the roadmap. Furthermore, to enable retrofitting, the team aims for backwards compatibility of the RCU® where feasible.

Close-up shot of electronic components and circuitry that compose the RCU® . In the center of the image, there is a circuit board with the word "arculus" displayed prominently. Surrounding the circuit board are multiple wires of different colors, including red, green, and blue wires.
The RCU® is constantly going through iterations that involve countless tests and measurements

One of many challenges

The continuous iteration approach allowed the team to overcome a number of obstacles that appeared during the development of the RCU®. For Tobias, “One of the greatest challenges was integrating both power electronics that favour wide and thick copper structures on the PCB and high-density logic systems with high-speed communication – that favour the exact opposite – on the same PCB.”

While having both on the circuit board is possible, it requires special fabrication technology. And that’s what the team tried to avoid, as it would lead to greater complexity, longer lead times, and higher costs. The final solution for the issue involved a mix of creativity, electronics, and craftsmanship, and you can read the full story told by Tobias himself here.

What’s next for the RCU®?

As previously mentioned, robotics developments at arculus are characterised by constant iterations. Therefore, as the RCU® has reached a consistent state, its future developments are constant updates and modernisations. According to Tobias, the next big step planned is updating the Linux module. “As it’s so deeply integrated into our system, we shied away from updating it for a long time. But we have now enhanced most parts of our robot. Thus, we are now at a point where we can really profit from an improved central computing system”, he explains.

Close-up vision of the version 2.2 of our RCU®

The plan is to switch to an enhanced SOC (system on chip) of the latest generation on Nvidia’s Linux modules. And that promises a significant increase in performance and efficiency. “At the same time, we will also integrate a bunch of other smaller improvements”, says Tobias. But readers will have to remain curious about these for now.

The true impact of it all (TL;DR)

In conclusion, the RCU® serves as the beating heart of the arculee, centralising power distribution and orchestrating seamless communication among various subsystems. Its in-house development empowers arculus to tailor this control unit precisely to meet different customer needs, resulting in enhanced robot performance and adaptability.

The continuous iteration approach to development, demonstrates arculus' commitment to innovation. With the RCU® at the core, we continue our journey towards pushing the boundaries of robotics, aiming to integrate the latest generation of Linux modules to further elevate the arculee's capabilities. As the heartbeat of arculus' robotics solutions, the RCU® paves the way for a future of excellence and advancements in autonomous mobile robotics.

“Learning is the key to good engineering. Everyone makes mistakes while designing today’s complex systems, as many challenges are not obvious until someone has faced them. But it is important to grow with these and do it better next time.”

Tobias Schwering, Senior Electronics Developer

August 8, 2023

Rising Above the Fear of Robots in the Age of Automation

Many believe that robots pose a threat to humanity. As they continue infiltrating various aspects of our lives, this raises intriguing questions about our relationship with this technology. In this blog post, we will discuss the origins of the fear of robots, its psychological underpinnings, and how we can overcome the terror of our robotic counterparts.

The fear of automation and robots is not new. Most people had reservations when automation started increasing in the 1950s. They worried that AI and robots would destroy jobs or change society in alarming ways. Little did they know that new industries would emerge due to automated solutions.

The psychology behind the fear

The notion that robots could harbour hostile intentions towards humans exemplifies our relationship's intricate nature. This apprehension, commonly referred to as Robophobia, prompts us to delve into its psychological underpinnings. By examining prevalent beliefs, we can gain insight into the origins of this anxiety. So here are some of the most common fears:

  • Robots could be harmful to our health:

Many individuals have safety concerns regarding autonomous machines, as they perceive them to be dangerous. The greater the robots' capabilities, the more intricate they become. As a result, people may worry that the robots are prone to malfunction, even with multiple safety features.

  • Dependence on automation:

Some show resistance because they believe the world will become overly dependent on robots for different tasks. As a result, humans would lose their proficiency in certain skills and the autonomy to make informed decisions. According to this belief, automation can further create social isolation due to decreased human interaction within the workplace.

Mint coloured futuristic warehouse showing different types of robots working in harmony. In the foreground, there are four AMRS with wheels. A tall robotic-arm-like figure can also be seen on the right.
AI-generated image of a futuristic warehouse
  • Uncertainty is stressful:

The fast-paced progress in robotics is surpassing our society's capacity to fully understand the potential outcomes. As a result, people are becoming worried because they cannot predict the effects of incorporating robots into our cultural, economic, and social spheres.

  • Impact on jobs:

Many individuals argue that they will lose their jobs due to automation. It is true that technological advancements result in job disruption, and their fear is understandable. However, it is essential to note that robots take over repetitive and mundane tasks, allowing workers to redirect their skills to more complex tasks.

Source: McKinsey

Overcoming the fears

Many people believe that automation will lead to job losses, but in reality, it will simply change the nature of work. A report by McKinsey predicts a decline in demand for physical and manual skills by 2030, but an increase in demand for workers with different levels of technological proficiency. As advanced technologies become more prevalent, workers must develop new skills and adapt to new innovations.

It's important to understand that humans are the driving force behind the creation of robots. Teams of designers, engineers, innovators, and technicians work together to bring these machines to life, each bringing their own expertise, skills, and perspectives to the project. Ultimately, robots are simply products of human creativity.

Those who fear robots can also find comfort in the fact that companies building these mechanical machines must also follow mandatory safety standards. Such measures are in place to ensure that robots are safe to use in the diverse applications they were built for. For example, the LiDAR sensors in arculee, our Autonomous Mobile Robot (AMR), can detect a person inside the hazardous zone and stop immediately, thereby preventing accidents and injuries.

In a nutshell

As we navigate the fears and uncertainties created by robots, it is only fair to remember that throughout history, technological advancements ultimately led to job transformations and the emergence of new industries.

Robots are only there to execute tasks for which they were designed and programmed. On the other hand, humans' unique skills and qualities, such as creativity, critical thinking, and adaptability, will always remain invaluable to the evolving workforce. Therefore, it is crucial to evaluate human-robot collaboration benefits rationally. Rather than resisting them, it is in our best interest to perceive them as empowering tools.

July 11, 2023

Faster, Smarter, Better: Intralogistics with Autonomous Mobile Robots

As businesses seek to optimise their operations, Autonomous Mobile Robots (AMRs) have become a reality for intralogistics in the 21st century. We now see robots alongside humans, navigating complex environments and handling materials in factories. In this blog post, our Production Manager Thorsten Mersdorf explains how AMRs improve efficiency in various industries and transform how we look at intralogistics.

Autonomous Mobile Robots (AMRs) are now common in distribution centres, production facilities and warehouses. They are compact, driverless vehicles that transport loads or materials without a fixed, predetermined route. As the name implies, the primary purpose of deploying these robots is to autonomously drive any goods from a given source, to a given sink within the industrial workflow.

Thorsten Mersdorf is leading the AMRs' prototyping, commissioning, production planning and administrating processes, concerning quality management at arculus. He defines them as:

“In fundamental terms, I would describe AMRs as robots that do not require an additional infrastructure for navigation and orientation within the intralogistics system.”

Thorsten Mersdorf, Production Manager
Two men are standing in a robot testing area. The man on the left is wearing a dark blue jacket. He is smiling with glasses on and has a beard. The man to the right of him is also smiling and wearing glasses. Both men are looking at their laptops.  On either side of them there are windows letting natural light into the room, illuminating their faces as they look down at their laptop screens. Behind them, on the floor, is an arculee.
From left to right: Thomas Fuhrmann (Software Engineer) and Thorsten Mersdorf testing one of the arculee Backpacks

What do Autonomous Mobile Robots bring to the table?

AMRs are becoming increasingly popular because of their versatility and quick integration into existing infrastructures. Compared to manual operations, using them in a facility offers many benefits to businesses. Some advantages include reduced labour costs, more efficient work processes, enhanced flexibility, and safe human-robot collaboration.

The two most unique features that contribute to their high performance are:

  • Navigation: AMRs can plan and execute their routes autonomously. The technologies they use, such as high-quality cameras and laser scanners, are responsible for localisation, mapping, and adjustment to unforeseen environmental changes in the facility. If there are obstacles, AMRs reroute and complete their task without causing significant delays. This feature makes the navigation of these robots in the environment more intelligent and efficient.
  • Flexibility: The infrastructure in production facilities and warehouses needs to adapt rapidly too, due to frequent product, process, and market changes. This is where the flexibility of AMRs comes in handy as "Autonomous mobile robots can quickly adapt to the changing environment.", adds Thorsten. This capability to meet changing layouts is one of the reasons why they are so cost-effective.

Autonomous Mobile Robots in the bigger picture

"Industries such as automotive, food, and logistics have already implemented AMRs for different use cases.", says Thorsten. The overall intralogistics system may sound complex, as one fleet incorporates different sizes of robots and infrastructure for logistics and production. "Nonetheless, the applications of AMRs are so diverse that other core industries are either considering adopting them or are actively working on specific automated implementations.", he continues.

Here's a closer look at two of the main use cases for AMRs:

  • Goods-to-Person (G2P) picking:

In a G2P picking system, the AMRs lift up the goods and drive autonomously to the worker at the picking station. It allows efficient collection of items without requiring employees to walk around the workplace. As a result, there is an improvement in picking accuracy and a reduction in workers' fatigue.

  • Pallet handling:

AMRs also transport pallets in warehouses and distribution centres. Throughout the pallet handling process, these robots ensure precise navigation and collision avoidance, thereby reducing the risk of accidents, as well as streamlining the process.

A warehouse setting at a showcase. It represents a VNA use case with Jungheinrich trucks and arculees doing the automatic pick and transport of goods.
arculees operating at an implemented VNA system
  • AutoVNA Use Case as an extension of pallet handling:

One of the innovations in pallet handling is AutoVNA. It uses AMRs for vertical transportation between the warehouse and a picking station and the VNA (a very narrow aisle) for horizontal handling within the warehouse. Together, they form a compelling combination of two transport systems and may help reduce infrastructure needs, such as handover stations in the future.

Insights into the arculee S

From building our first AMR to receiving the statement of conformity from TÜV Süd Product Service GmbH, the arculee has come a long way. The robot's advanced components, such as the high-quality 360° sensors, ensure safety for humans working alongside it. This safety function enables the arculee to detect a person or an object and immediately stop if they are close.

An arculee S standing diagonally in front of the camera in the centre of the image. Behind it is a warehouse shelf with some pallets and boxes.
arculee S all set to navigate in the warehouse

The arculee S can also recognise load carriers of different sizes and efficiently handle a load capacity of up to 1000 kilograms. Furthermore, our robots can conveniently integrate with the host system (for central data processing), thanks to the VDA5050 interface. This protocol standardises the communication between the AMRs and any fleet management software to eliminate compatibility problems.

In addition to the capabilities mentioned above, the latest versions of the arculee S come with an extension option called Backpack. An arculus Backpack is a piece of equipment mounted on the arculee to transport pallets or other load carriers. The extended equipment also has sensors to detect a pallet's availability and correct position in order to enable safe transportation.

AGVs or AMRs?

Automated Guided Vehicles (AGVs) also transport materials but in a different manner. Wires, magnetic strips or sensors typically installed on the floor, guide them through fixed routes to perform repeated tasks. When AGVs encounter obstacles, they usually just stop instead of driving a detour around the obstacle like an AMR could do.

Thorsten uses the Pearl Chain Model (a concept often applied to automobile production systems) as an example to explain the difference. A pearl chain requires a stable flow and sequence of transports. Rerouting is therefore optional. He says, "In a stable system, where a robot has to make multiple rounds on a predefined path, from let's say, A to B, AGVs make more sense.". Therefore, "Using AGVs in the direct assembly environment of an automotive plant can be more advantageous than using the AMRs.", he continues.

Unlike AMRs, Automated Guided Vehicles may have limitations in terms of adaptability and flexibility. But their reliable technology for example, in terms of navigation, is one of the reasons they are used in the automotive industry. Therefore, depending on the specific use case, Thorsten believes both technologies have the right to exist in different industries.

Manoeuvring into the future

With increasing possibilities for logistics automation, use cases for AMRs will likely change in the future. Although it is already evident in logistics processes that have integrated AMRs into their system, automated control is gradually becoming more central. Thorsten views the control centre of a factory as a collection of puzzle pieces. He explains, "Currently, we have a different piece of the puzzle for pre-assembly, production, logistics, or even incoming goods. Eventually all pieces will come together to form one environment or system. So, there will no longer be several use cases or sub-systems, but everything under one umbrella."

Thorsten is convinced that further developments in core components, such as cameras and other sensors, as well as new technologies like machine learning, will positively impact the capabilities of AMRs and thus the demand for AMRs in the coming years. This may enable the AMRs to learn from each other. As a result, we may expect autonomous mobile robots to react more accurately, efficiently, and flexibly in all situations and environments.

June 27, 2023

Predictive Analytics for AMRs: Insights from the AI REGIO Experiment

The integration of artificial intelligence (AI) into manufacturing processes has revolutionised how industries operate. The AI REGIO project, funded under the European Union's H2020 Research and Innovation Programme, has been instrumental in fostering collaboration among Digital Innovation Hubs (DIHs) across Europe. In partnership with arculus, they launched an experiment to optimise robotic systems through predictive analytics and maintenance. This blog post explores the objectives and outcomes of this groundbreaking experience conducted by arculus and AI Regio in cooperation with Forschungszentrum Informatik (FZI).

What is Predictive Analytics?

Predictive analytics uses statistics, Artificial Intelligence (AI), data mining, and modelling techniques to forecast future outcomes. This method analyses current and historical data patterns to determine if similar events are likely to happen in the future. This allows businesses to adjust their strategy, to take advantage and prepare for probable future occurrences, leading to improved operational efficiency and reduced risk.

How does Predictive Analytics work?

Data scientists utilise predictive models to find connections between various components within specific datasets. Following the collection of data, a statistical model is created, trained and adjusted, in order to generate predictions.

Predictive Maintenance

Predictive models have a wide range of applications across numerous and varied fields. Primary use cases include weather forecasting, customer service, voice-to-text translation, and investment portfolio strategies. In the scope of the experiment conducted by AI REGIO with arculus and FZI, the focus was on the so-called predictive maintenance.

In the background, there is a blurred image of a man in a suit pointing his finger at visual representations of the elements that constitute predictive analytics. Namely: Pattern recognition, artificial intelligence, automation, neural networks, algorithm, data mining, and problem solving.

Predictive maintenance uses advanced algorithms to anticipate and prevent equipment malfunctions. By analysing patterns and trends in historical data, predictive maintenance models can forecast when machines are likely to experience a breakdown. This data-driven approach enables timely interventions, optimises maintenance schedules, minimises unplanned downtime, and reduces overall repair costs, by addressing issues before they escalate.

A report by the Deloitte Analytics Institute quantifies the benefits:

“On average, predictive maintenance increases productivity by 25%, reduces breakdowns by 70% and lowers maintenance costs by 25%. It is based on advanced analytics and marks a new way of organising and implementing maintenance on an industrial scale.”

The Experiment

The main goal of the experiment conducted by AI REGIO with arculus, was to leverage predictive maintenance models to make robots more sturdy and efficient. In this context, instead of focusing on optimising control algorithms typically associated with robot navigation, the aim was to improve and optimise processes that could significantly impact arculus' scaling efforts. These include, among others:

  • Optimisation of maintenance intervals;
  • Reduction of regular service intervals (like scanner cleaning) by making service calls on a need basis rather than schedule-basis;
  • Early detection of sensor faults (Lidar, IMU, Camera) to ensure proactive resolution of issues.
Close up of the arculee showing its Lidar sensors.
Proper functioning of the arculee’s Lidar sensors is essential for navigation

The following requirements were defined as success metrics:

  • Accurate and securely repeatable predictions of specific situations;
  • Continuous and automatable data pipeline from customer projects.

The results

The experiment yielded promising results. Firstly, the team successfully connected Internet of Things (IoT) data streams from the robots by utilising a Machine Learning (ML) technique known as automatic schema recognition. This allowed for seamless integration and analysis of the data collected. Furthermore, by creating processing pipelines built on both rule-based and learning-based algorithms, the experiment enabled efficient analysis and prediction of maintenance needs.

The study also established a model repository, featuring pre-trained models designed to facilitate predictive analytics for Autonomous Mobile Robots (AMRs). These models trained using ML techniques on extensive historical data and provided accurate predictions of maintenance requirements. Lastly, the experiment introduced a pipeline element generator to optimise the maintenance process further. This tool allows for the quick creation of new models tailored to specific use cases through a technique called few-shot learning.

Close up of an engineer's hands using a machine to gather electric waves from the arculee's control unit.
Data streams from the robot are a key part of predictive modelling

Next Steps

The next step in the experiment will involve developing a high-performance algorithm based on real-life data. This algorithm will focus on detecting dirt on the laser scanners of the AMRs, enabling proactive notification to the maintenance team for prompt cleaning. With this approach, the trial aims to ensure the AMRs' optimal performance and longevity, as well as minimise any potential operational disruptions they may face.

Meet the Players

AI Regio

The goal of AI REGIO is to enhance collaboration between DIHs across Europe. The plan is to improve regional DIHs' services to small and medium-sized (SMEs) manufacturing businesses. These improvements will be made on three different levels:

  1. Policy Impact

AI REGIO coordinates smart specialisation strategies across European regions and beyond to help scale innovations to global markets. This builds on the Four Motors for Europe movement and the I4MS Community and Innovation Collaboration platform, fostering closer cooperation.

  1. Technological Impact

The AI REGIO uses previous EU-funded projects like L4MS and AI4EU to create Digital Manufacturing Platforms. These platforms are integrated into the services offered by Digital Innovation Hubs. As a result, Digital Manufacturing Platforms receive support for their business and social impact challenges, while also expanding their AI-enabled technological assets.

  1. Business Impact

In AI REGIO, both DIHs and SMEs collaborate on 30 regional application experiments that use AI technology. These experiments focus on helping SMEs adopt AI and include considerations for skill development, privacy, and sovereignty preservation.

FZI

The FZI Research Centre for Information Technology is a non-profit organisation that stands for applied research and technology transfer. Since its foundation in 1985, it has been conducting research in various fields related to computer science. Under the motto "Research is the engine of the future", the institute claims to work towards responsible future shaping.

June 15, 2023

Precision On Wheels: How AMRs Tackle Error-Related Costs

Many companies seek innovative solutions to enhance accuracy, efficiency, and cost-effectiveness in today's dynamic business landscape. Thanks to Autonomous Mobile Robots (AMRs), various industries have been able to automate tasks formerly prone to human error. This blog post will uncover how adopting AMRs can benefit businesses by reducing error-related costs.

In an ideal logistics world, employees would operate order fulfilment processes flawlessly and with no errors. The harsh reality, however, is that mistakes are inevitable and can significantly cost businesses time, money, and in some cases, reputation. Studies suggest that the average error rate in warehouses or distribution centres ranges between 1%-3%, compromising a company's profitability by 13%.

The root cause of error-related costs

Before evaluating how technology can reduce or eliminate inaccuracies, it’s essential to understand why and where such blunders occur. One common human error in logistics happens during manual picking and packing. This is simply the selecting of incorrect or damaged items, mistaking quantities, or damaging packaging. In the best case, the mistake might get detected before the order leaves the facility. The potential loss in this situation could be time or the need to employ extra workforce.

However, if the order gets delivered to the customer without taking measures to rectify the fault, the consequences are more significant. Companies must pay additional expenses, including customer refunds, return process costs, and shipment. They also have to deal with dissatisfied customers, who may lose trust in the company’s credibility because of wrong or damaged products. Ultimately, organisations pay the price for errors instead of reaping profits.

Source: AMWARE

Fortunately, businesses can have more optimised and responsive workflows by incorporating AMRs, like our arculee, in distribution centres, production facilities, and warehouses. They are incredibly versatile, speeding up the picking process and guiding associates through tasks such as picking and packing, inventory management, and the efficient sorting of items. Companies that deploy these robots see minimal faults, increased productivity, and drastically diminished costs.

Fewer mistakes, greater productivity

AMRs can reduce error rates in several ways, optimising the order fulfilment processes to enhance accuracy and efficiency. Some of them are listed below:

  • On a primary level, Autonomous Mobile Robots use their advanced sensors and maps to determine and navigate through efficient pathways and reach the correct picking station. With this capability, employees only have to worry about collecting the right items and confirming the pickups.
  • When AMRs integrate with a Warehouse Management System (WMS), they receive real-time instructions and updates regarding inventory, orders, and task priorities. It heavily reduces the chances of miscommunication that can lead to a potential fault.
  • When robots take over repetitive tasks in warehouses and distribution facilities, workers experience mental and physical relief. It allows them to use their time more effectively by focusing on important tasks, which helps them maintain performance throughout the day. As a result, employees are more dedicated and focused, leading to a reduction in error rates.
Autonomous Mobile Robots transporting load carriers in a warehouse

In conclusion

Many industries are adopting Autonomous Mobile Robots (AMRs) to improve their workflows and reduce errors and costs. This trend is expected to continue, leading to more efficient and successful operations. Automation, including the use of AMRs, is critical to the future of logistics, enabling a more reliable and error-free world.

June 6, 2023

Empowering Robots: Insights Into AMR Backpacks for Efficient Intralogistics

In the world of Autonomous Mobile Robots (AMRs), the term "AMR backpacks" refers to a specific range of attachments that assist the robots with object transportation. To better understand how these attachments empower our arculees, we sat down with Fabian Gebert, Robotics Engineer at arculus. Here are his insights into safety requirements, customisation options, and much more.

Understanding the basics of AMR backpacks

Efficient material transport is essential in the increasingly demanding field of intralogistics. In this dynamic environment, backpacks empower AMRs to become agile material carriers, revolutionising operations and unlocking new levels of efficiency and productivity. As Robotics Engineer Fabian Gebert explains, “A backpack is an attachment for the arculee, and it’s used to detect and transport different objects.”

Without a backpack, the arculees rely on load carriers called “tables”. These large modules are particularly well-suited for applications where box transport is the primary focus and handover stations are not required. However, in the context of VNA (Very Narrow Aisle) warehouses, backpacks present a range of distinct advantages. Unlike tables, backpacks offer a compact design that facilitates agile manoeuvrability within confined spaces, thereby optimising the utilisation of the available area. They also incorporate advanced technology, ensuring secure and stable pallet transportation, reducing the risk of accidents or damage along the way.

Yellow arculee positioned underneath a grey table with a pallet on top. On top of the pallet in a box.
Tables have a much larger footprint than backpacks and are unsuitable for VNA use cases

The arculus backpack arsenal

The standard arculee S backpack is designed to transport the classic EURO and Industrial pallets (EPAL 1, EPAL 3, and HD 1208). Its integration with the robot creates a powerful combination that enables seamless transport of goods weighing up to 1 tonne. It also features an identification plate, which facilitates effortless recognition by the AMR’s system and allows for seamless integration into existing workflows.

The AMR backpack also features light-barrier sensors that ensure accurate pallet detection and proper centring, minimising the risk of accidents and damage to goods and infrastructure. It also incorporates strong grip tape on the contact surfaces, which prevents pallets from slipping off even in demanding conditions. Both features work together smoothly, delivering a reliable and secure pallet handling process.

Yellow arculee with a standard grey backpack mounted on top
arculee S with a standard arculus backpack on top

Backpack customisation at its core

Fabian explains that the customisation possibilities of AMR backpacks at arculus are numerous: “Sometimes a customer already has some shells or environment restrictions, and then we just need to modify our prototypes in a way that fits their needs. But sometimes we get requests for entirely new and bespoke developments.”

This is exactly what happened when a customer requested a new addition to the arculus portfolio: the conveyor backpack. As the name suggests, the system incorporates a conveyor belt to enhance the pallet handling processes. Its primary purpose is to safely pick up Euro-Pallets from a fixed station and transport them to a conveyor station. There, the backpack utilises its own conveyor mechanism to transfer loads of up to 250kg, ensuring precise positioning and controlled movement.

The system incorporates two inductive sensors that facilitate alignment with the conveyor mechanism. To maintain safety, the backpack is equipped with end-stops that act as safeguards, preventing the pallets from being carried too far. Additionally, light barriers in the backpack ensure secure positioning of the pallet. The solution also features emergency stops on all sides, preventing unintended movement and providing very safe operation. With its seamless integration of a conveyor system, the solution streamlines pallet handling processes, improves workflow efficiency and contributes to overall operational effectiveness.

Installation of a conveyor backpack on the arculee S

Testing and validation of AMR backpacks

When it comes to ensuring the functionality and safety of the AMR backpack before deployment, rigorous testing and validation procedures are essential. These tests encompass fully functional assessments, including evaluating the handover process, detecting the potential slippage of goods, assessing the alignment of loads, and determining the maximum cargo capacity.

As Fabian explains, the testing process involves various scenarios to evaluate the performance of the AMR backpack. For instance, the team uses simulations to assess its functionality during conveyor pick-ups, its ability to detect and respond to obstacles, and its stability and safety during emergency stops. The goal is to ensure the backpack remains secure while providing optimal performance in real-world situations.

Fabian wearing a red t-shirt and sitting in front of a large monitor where a close up of a 3D rendering of a standard backpack can be seen. His back is turned to the camera. To his right is a laptop not being used, but connected to the monitor. In the background there is a white board with some calculations, which are out of focus.
Fabian running backpack data on CAD

Metrics of success

In addition to rigorous testing, the team evaluates the effectiveness of backpacks using various performance metrics, such as cost, manufacturability, and operation time. For this, field evaluations and simulations play a crucial role in assessing the backpack's performance. The results obtained in these procedures provide the engineers with valuable insights into improving the solutions’ efficiency. Operation time for example, measures the time required for an arculee equipped with the backpack to complete tasks such as load pick-up and drop-off. Other factors considered include reducing manufacturing costs, evaluating component feasibility, and meeting project deadlines.

"Testing and evaluating the AMR backpack are crucial steps to ensure its safety and functionality."

Fabian Gebert

Technical hurdles

The development of AMR backpacks has various technical challenges, particularly when it comes to safety assurance. As Fabian explains, “Everything we do comes back to safety. Safely detecting a station, safely detecting the object on the AMR backpack, safely detecting everything. That's one of the major challenges we face during development.”

Integrating the backpack with the arculee's control system also poses its own hurdles, particularly in software development, since communicating vital information between the backpack and the arculee's control system is critical for proper functioning. For instance, if the backpack's motor initiates movement while in a station, it must communicate this to the arculee, preventing it from engaging in any actions that could compromise safety. Effective communication and synchronisation between the backpack and the control system are essential for smooth operations.

Cross-team collaboration

The project’s multidisciplinary nature further adds complexity, requiring expertise in diverse fields such as electrical components, software integration, and mechanical design. Effective communication between teams plays a crucial role, as it ensures proper calibration and integration of all technical aspects and enables the development squad to approach challenges from various perspectives. By fostering effective communication and mutual understanding, the developers can overcome hurdles and ensure a smooth integration of the backpack with the arculee, ultimately leading to a successful and well-rounded product.

Two engineers working on installing a conveyor backpack on the arculee
Fabian and another team member installing a conveyor backpack on the arculee S

Packing it all up

The insights provided by Fabian Gebert offer a practical understanding of the arculee backpacks and their role in intralogistics. These attachments enable AMRs to become agile material carriers, offering distinct advantages over traditional load carriers. With features like accurate pallet detection, proper centring, and strong grip tape, the backpacks ensure secure and efficient pallet transport. Customisation options and rigorous testing further highlight arculus' commitment to delivering safe and functional solutions. By integrating advanced technology and fostering cross-team collaboration, arculus enhances pallet handling processes and contributes to operational effectiveness in diverse industrial environments.

May 10, 2023

Understanding DevOps: The arculus Guide to Faster Delivery

DevOps has become crucial to software development, focusing on continuous delivery and cross-team collaboration. More than a simple methodology, it’s better understood as a cultural philosophy that helps companies achieve more efficient and reliable software deliveries. In this blog post, we will go through the basics of the DevOps practice and learn from engineer Esteban Bosse about how it is used at arculus.

What is DevOps

DevOps – if you are into tech, then chances are you’ve heard of it before. In simple terms, it means bringing software development (Dev) practices into the Operations (Ops) world. Although it started simply as an approach to enable faster development, today’s demanding tech market makes it hard to imagine any software release without DevOps.

The DevOps Culture

DevOps is more than just a development methodology but rather a cultural philosophy. It derives from the Agile methodology, emphasising collaboration to deliver applications. When adopting DevOps, organisations prioritise improving the flow and value delivery. Companies achieve this by encouraging developers, operations staff and other stakeholders to work together to identify and resolve issues quickly and to continuously improve the software development process.

Two female engineers and one male engineer are standing in front of a high desk and looking at two laptops. In the background, there is a mint coloured arculee and a transport table.
Cross-team collaboration is a crucial element of the DevOps culture

Along with collaboration, the DevOps philosophy also encourages fast feedback and iterative improvement. In a traditional development model, feedback from operations teams can be slow or non-existent, leading to delayed bug fixes and increased downtime. With DevOps, operations teams are involved in the entire software development life cycle, ensuring timely and actionable feedback. This enables developers to rapidly improve their application code, ensuring reliability and stability in any release.

Another essential element of the DevOps culture is automation, which increases efficiency and reduces the risk of human error. Esteban Bosse, DevOps engineer at arculus explains, “If you find yourself performing a task more than once, that means you should automate it. Repetitive tasks are not only time-consuming – but they also increase the chances of making mistakes.” Automated tasks include testing, deployment and monitoring, which can help to streamline the development process and reduce the time and effort required to release new features or updates.

The DevOps Lifecycle

The DevOps philosophy involves seven phases in a continuous cycle, which is why it is represented by the infinity loop below:

Visual representation of the DevOps cycle (explained in the text). The infinite loop is mint coloured and the background is black.
The left part of the infinity loop represents the development processes, while the right half showcases the phases of the operations cycle

Here is a brief overview of each stage of the DevOps lifecycle:

  • Plan: this stage comprises all activities that occur prior to writing the first line of code. The goal is to create a product roadmap that guides upcoming developments, so that the team can organise resources and priorities, as well as align and track projects.
  • Create: also referred to as build, this is when developers write code with version control, enabling the coordination of changes made by various developers to the same code base. It is a crucial factor in enhancing the velocity of the development process.
  • Verify: sometimes also named test, this is the stage focused on certifying that the code is functional. This process relies on security testing, code quality analysis, parallel execution and automation.
  • Release: at this stage the code is ready for deployment in the production environment. Once it has passed all required tests, the operations team schedules or deploys multiple releases to production.
  • Deploy: this phase involves pushing code updates into the production environment as soon as iterations are tested and ready.
  • Configure: this stage involves setting up, managing and maintaining application environments. Automation plays an important role here, as it handles the complexity of environments across servers, networks, and storage systems.
  • Monitor: this part of the process is about tracking the status of software, infrastructure and networks. It raises alerts to problems and increases security and reliability.

What Enables DevOps

DevOps relies heavily on a set of practices called Continuous Integration and Continuous Delivery (CI/CD) to achieve its efficiency goals. The method uses ongoing automation throughout the DevOps lifecycle, from creating and verifying to releasing and deploying. If implemented correctly, it allows code changes to be automatically tested and pushed out, resulting in much faster code delivery and therefore, faster release of new features into the market.

What is Continuous Integration (CI)?

Continuous Integration is a practice that involves integrating code changes into a shared repository, which automatically detects and promptly resolves problems. With CI, developers can automate the process of building, testing, and validating code changes as soon as they happen. This minimises the possibility of code conflict, even with multiple developers working on the same application. With CI, DevOps teams can improve code quality while accelerating feature delivery.

What is Continuous Delivery (CD)?

Continuous delivery works in conjunction with CI, taking it a step further. After the code has been tested and built as part of the CI process, CD takes charge during the final stages to ensure it’s bundled with all necessary components for deployment to any environment at any time. The CD process encompasses various processes, such as infrastructure provisioning and application deployment.

How we use DevOps at arculus

At arculus, we rely on DevOps practices to ensure a more stable software delivery process for our robots. A prominent example is the arculee “brain”, which consists of thousands of lines of code that must be built, tested and deployed into our fleet. As Esteban explains: “The infrastructure provided by DevOps helps developers run their code in the robots as fast as possible while also running automated tests and static code analysis.”

A DevOps engineer talking to a female colleage.
Esteban Bosse (DevOps Engineer) talking to a colleague at the arculus Munich office

Another benefit our developers can count on, thanks to DevOps practices, is reproducible builds. “That means if you send the same code to our infrastructure twice, you will end up with the same result. That's important because of the quality of things; otherwise, you can test the same code twice, and the results would be different”, clarifies Esteban.

The bottom line is that “our CI/CD can build source code much faster than developers’ laptops. They can install the software in the robots to test it without moving files around, which minimises the chance of human mistakes. Also, when an error occurs in the robot, it is directly stored in our infrastructure. With several errors collected, the debugging process gets much easier for the developers.”, continues Esteban.

Customer Success

The DevOps practices at arculus don’t only benefit the robots still being tested and developed. The fleet of arculees already operating at customers’ facilities also receive software releases. This process happens through the so-called OTA (Over The Air) agent. “What is interesting about this is that we can still push software updates even if customers don't allow the arculees to connect to the internet. Thanks to the CI/CD infrastructure we have built, we can host replications of the robots’ archives so that the arculees can install update packages.”, explains Esteban.

3D rendering of a human figure holding a computer and transferring updates to the arculee.
arculees running at customers’ facilities can stay up to date thanks to the OTA agent

“It’s amazing how easy it is, thanks to the infrastructure we have in place, to install software releases on the arculees in different parts of the world just from the comfort of my home, knowing the software was well tested.”

Esteban Bosse, DevOps Engineer at arculus.

The Benefits of DevOps

Adopting the DevOps philosophy allows development and operations teams to collaborate more efficiently throughout the whole development and application lifecycle. Without DevOps, companies frequently encounter handoff friction, which causes delays in software releases. In fact, a 2020 DevOps Trends Survey conducted by Atlassian showed that 99% of respondents saw a positive impact on their organisation after implementing DevOps.

Developers at arculus can work more effectively thanks to DevOps practices

Here is an overview of the most common benefits enabled by DevOps:

  • Agility: companies with a DevOps team can release more stable deliverables with higher quality. Thanks to CI/CD, developers can count on the speed provided by automation.
  • Improved Collaboration: DevOps is built on a culture of collaboration between developers and operations teams, who share duties and work together. This makes teams more efficient and saves time when it comes to work handoffs and creating code.
  • Fast Deployment: DevOps teams can quickly deploy new features and release bugs by boosting the frequency and speed of releases, ultimately leading to a competitive advantage.
  • Quality and Reliability: CI/CD practices ensure that updates are functional and safe, improving the software quality. Real-time monitoring also keeps the team up-to-date on potential performance issues.

Summing it up

In conclusion, DevOps is a cultural philosophy that aims to improve software delivery by leveraging collaboration, feedback and automation. It involves a continuous lifecycle that is enabled by a combination of practices known as CI/CD. At arculus, DevOps practices are crucial to ensuring stable software delivery for the arculee, allowing the developers to push code faster and more efficiently.

April 5, 2023

Redefining Intralogistics Possibilities With Lithium-ion Batteries

Lithium-ion, or Li-ion, is a technology dethroning traditional lead-acid cells in major industries. Most electronic devices are powered by these batteries, from mobile phones to cameras to automated vehicles. In this blog post, we will uncover what these power cells are and how they have paved the way to become the leading energy source in intralogistics.

Lithium-ion batteries are a key enabler of the mobile device world. They have been a prevalent choice in consumer electronics due to their unique selling points: lightweight, high energy density, and maintenance-free. Because of these characteristics, in recent years Li-ion cells have become the number one choice of manufacturers from other industries, including aerospace, electric vehicles, and intralogistics.

Lithium-ion batteries significantly affect the performance of automated warehouse vehicles, such as forklifts, autonomous mobile robots (AMRs), and automated guided vehicles (AGVs). They are, therefore, a primary source of power for the intralogistics industry. "Li-ion batteries are one of the primary factors that impact the performance of AMRs. The traditional energy storage solutions are big and heavy in weight. Hence, our project, the arculee, would never have come this far without this technology.", says Carlo Fitz (Managing Director at arculus) in an interview with DW.

Understanding the mechanism behind Lithium-ion batteries

To better understand how lithium-ion batteries work, it's essential to examine their fundamental components. The lithium ions are electrically charged particles that move in the battery to generate an electric current. The cathode, or positive electrode, serves as the primary source of lithium ions and determines the battery's voltage.

During charging, the anode, or negative electrode, triggers an electric current to pass through the external circuit and stores lithium ions. A thin insulating material called a separator prevents electrons from passing between the cathode and anode while lithium ions move through. Lastly, the electrolyte, which consists of a liquid mixture of salts, solvents, and additives, is responsible for conducting electricity.

A diagram with a visual representation of how Lithium-ion batteries work. The background is black. The lithium-ion cell is represented by pink sides and a purple interior.
The diagram shows the key components inside the Li-ion battery

As the name implies, the functioning of lithium-ion batteries revolves around the movement of lithium ions. During the charging process, the cathode releases lithium ions (Li+) which move through the electrolyte and get stored in the anode, allowing the battery to accumulate energy. At the same time, electrons flow through the external circuit from the positive to the negative electrode. Once the movement of lithium ions and electrons ceases, it indicates that the battery is fully charged and ready to be used.

In contrast, during discharging, the ions flow in the opposite direction, from the negative to the positive terminal through the electrolyte. Electrons follow the same direction as ions through the outer circuit to power the device. When all the ions move back, the battery is fully discharged and must be charged again.

Lithium-ion batteries versus lead-acid batteries

While Li-ion power packs are emerging as a top pick, lead-acid batteries are on the way to becoming obsolete. Taking a closer look specifically at intralogistics, here's how lithium-ion batteries have the edge over their lead-acid counterparts:

High energy density:

Lithium-ion batteries are extremely powerful, usually with an energy density between 100 and 265 watt-hours per kilogram. High energy storage makes them a more stable and faster powering source than lead-acid batteries. This is crucial to enable automated vehicles to carry out complex tasks in multi-shift operations.

Furthermore, Li-ion batteries typically do not need any backup, because they go into charging mode between shifts. This means users don't need to remove the cells from the automated vehicles for charging, which saves time and costs.

No maintenance, lower costs:

Another way in which Li-ion batteries save cost and money is by ensuring that end-users don't have to worry about maintenance. Compared to lead-acid cells that need to be refilled with electrolytes or demand a separate infrastructure, Li-ion technology has no such requirement, thus offering a hassle-free solution.

Low self-discharge:

Most batteries, including lead-acid cells, lose their charge when disconnected from the device. But that's not the case with Li-ion batteries. These rechargeable cells have a substantially low self-discharge rate, and, if fully charged, can retain power much longer without causing any damage to themselves.

Emission-free:

Automation fosters green intralogistics, and the use of lithium cells in automated vehicles can boost sustainability efforts. They do not release dangerous gases during operation or charging, reducing carbon emissions in electric vehicles by around 20%.

Higher Usable Capacity

Compared to conventional solutions, Li-ion batteries have a higher usable capacity, with a discharge range of 80-100%. The result is more consistent power, allowing vehicles to operate longer on a single charge.

A 3D rendering showing the different uses of Lithium-ion batteries in intralogistics equipment. The background is a gradient of blue tones. In the center in a light circle, slightly tilted towards the screen. The circle is made of 3 arrows, representing a continuos cicle. Inside the circle are different 3D renderings of intralogistics machines, like storage solutions and forklifters.
Lithium-ion batteries have multiple applications in intralogistics

Benefits of using Li-ion batteries in the arculee

Li-ion technology is one of the key factors that enable the sophisticated capacities of our AMR. For starters, these batteries allow the arculee to operate for eight uninterrupted hours on a single charge. Additionally, Li-ion cells can communicate with smart systems and provide real-time updates about the time remaining before the battery is fully discharged. This feature ensures that the arculee has sufficient time to automatically reach the nearest charging station.

The future is lightning

Batteries have become a large part of our mobile world, and Lithium-ion technology is here to stay. According to a report by Mckinsey, nearly 60% of lithium is extracted for producing batteries today, and this number can potentially rise to 95% in the near future.

arculus is an early adopter of this technology. Its advanced characteristics enable our AMR to transport heavy loads more efficiently and with minimum interruptions in the warehouse. Thanks to Li-ion batteries, we are proud to offer a solution that helps customers reduce costs and operate more sustainably.

The Lithium-Ion Story by Deutsche Welle

A documentary film by Deutsche Welle explores the extraction of lithium, the production of state-of-the-art cells and their use in Jungheinrich vehicles, including the arculee (from minute 38:28). Watch it below:

March 21, 2023

Modernising UX Design in Industrial Automation: The arculus Story

This story will take you through arculus' journey towards remodelling UX/UI design in industrial automation. Discover how the company is revamping its software ecosystem by continuously improving on traditional approaches in the field. The article highlights the adoption of modern technology and UX/UI design methodologies to enhance the user experience and prioritise user safety.

The Human Face Behind The Interface

The arculus software ecosystem is a complex solution that includes a fleet manager and a warehouse administration system. It serves as a single controlling interface for a fleet of Autonomous Mobile Robots running at any production facility. Such a versatile and intricate product requires delicate frontend work to ensure the user can take advantage of all its possibilities.

That’s where Axel Jäger comes in. Since January 2020, he has been responsible for leading the UX and UI teams at arculus. “I’m a developer at heart, but usually, I only spend half of my time coding. The other half I use for discussing ideas and helping the team solve problems”, he explains. But the passion for programming is not the only thing that binds him to his work:

“I have a lot of technology here at home because I enjoy it. It doesn’t feel like work research, which it is, because it's also part of my hobby. So I’m always getting my hands on the latest tech gadgets, like 3D printers, VR glasses or smartphones. And that allows me to keep up with the current trends in UX.”

Axel Jäger (Teamlead Frontend Development)

All the tech research and team coordination pays off: Axel has been at the forefront of revamping the arculus software, from an obsolete desktop client system to a web-based fluid application in just three years. Here is an overview of his little UI/UX revolution.

Axel is wearing a black shirt and sitting in front of a large computer monitor. He has a small plant and a glass of water on his right side. In the slightly blurry background, another employer can be seen wearing headphones and focused at work.
Axel Jäger (Teamlead Frontend Development) at our office in Gaimersheim

UX, UI and the mother of all questions

The first step to understanding Axel’s role within the software team is answering the most basic of questions: what are UX and UI designs? The Adobe definition claims, “User Experience (UX) design is the process of creating products (digital or physical) that are practical and usable.” And the User Interface “is an integral aspect of user experience (UX) that consists of two major parts: visual design, which conveys the look and feel of a product; and interaction design, which is the functional and logical organisation of elements.”

For the arculus software, a well-designed user interface and experience go beyond making the product enjoyable to use: it’s also a matter of ensuring material flow. “We are talking about a system that manages the stream of goods in a warehouse or production facility. So, if the user does something wrong, there is a real chance of major economic losses due to standstills”, explains Axel. “That’s why we need to offer a program that ensures the user can feel safe and confident when performing any actions”.

Modern UX design for an old-school industry

The concern with the correct flow of goods is not the only thing that makes working on the arculus software’s front end peculiar. Axel describes it: “Most modern UX is driven by consumer products, with cutting-edge interface designs. But arculus is in the industrial automation field, which tends to be quite conservative. And that’s evidenced by dated software solutions still in use today.”

But that’s about to change. With users increasingly accustomed to interacting with straightforward interfaces, training them to use outdated software is turning into a challenge. “We are currently seeing a transition from many players in the market, and we want to put arculus at the forefront of this movement”, explains Axel. “An example is that, although we don’t currently have touchscreen interaction planned, we still choose to incorporate paradigms from touchscreen interfaces, as users are already familiar with them”, he continues.

Another crucial step in modernising the arculus software ecosystem was changing the complete technology stack: from desktop client to web-based. With this change, Axel’s team could finally apply modern UX and UI methodologies to the software.

“Now, with our web-based tech stack, we have a designer who crafts every element of the interface. That gives us a clean-looking and fluid software, with animations and other elements of modern UI design”

Axel Jäger (Teamlead Frontend Development)
A mockup showing a dark mode view of the arculus software ecosystem's interface. There is a flat map of the operation featuring pink, blue, yellow, green, and cyan highlights. On the left there is a list of all robots and their respective battery status.
Dark mode view of the new web-based UI

Hard work pays off

In the new web-based software, users can count on a live 3D representation of the operation. It includes the depiction of all objects that interact with each other, such as vehicles, working stations or charging points. Things that need the operators’ attention are collected from the various subsystems into a common notification panel.

For Axel, a personal favourite feature is a newly-implemented approach for AMR repositioning. “The conventional idea would be to implement a drop-down menu. But we noticed that this would actually create more confusion, because it’s tough to identify each robot only by its number. So what we did was allow the user to pick the desired AMR from the 3D visualization. The system then recognizes exactly which robot the user wants to reposition.”

A screenshot of the web-based UI with a 3D map of a robot operation at the center. Three robots can be seen: two of them are not moving, and the third one has its route highlighted in green. On the left there is a list of object types: AMRs, Streets, Intersection, Shelf Locations. Underneath it there is a list of objects, featuring a series of robots and their respective battery levels.
View of the web-based UI featuring the 3D map visualisation

Upcoming Highlights

Although revamping the arculus software has already come far, innovation is a continuous process. The next significant development planned for the front end involves a common challenge in UX/UI projects: designing for different levels of technical expertise. The current solution is simple: a switch. It allows the user to choose between regular settings and expert settings. But that’s about to change.

“I want the software to be as easy as possible to use, regardless of who is on the other side of the screen. So there should be no differentiation between a standard and an expert user”, explains Axel. To achieve that, the team is currently in the process of challenging the expert functionalities. “We are looking at seldomly used features and asking ourselves why we even need them. Is this something we can eliminate by improving the system?” he continues.

Over shoulder view of a developer sitting in front of his computer. In his screen, there is a large piece of code in a black background.
Axel at work

The simplification goal is also at the core of another up-coming milestone: the improvement of Smart Side Editor, the feature used for creating a plant layout. In its current status, the user needs previous experience or technical support to draw new layouts. But Axel wants to change that. “We want to improve the street drawing method, for example so that anyone can use it. It should also be easier to run simulations and determine which layouts work better.” He concludes.

Tying it all together

In conclusion, arculus is successfully leading the charge in the transition from outdated solutions to modern, user-centric software in industrial automation. The transition from a desktop client to a web-based solution has enabled the application of contemporary design principles, leading to a clean, fluid and user-friendly interface. The focus on user safety and experience has resulted in a software ecosystem that enhances productivity and promotes a sense of confidence and comfort in users. With features like live 3D representation and intuitive robot repositioning, we are setting a new tone for UX/UI design in industrial automation.

“Good software should be ergonomic. Meaning: efficient, comfortable, and easy to use. That’s how it enables better performance and keeps the user in control”

Axel Jäger (Teamlead Frontend Development)
CONTACT

arculus GmbH
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D-81541 München

info@arculus.de