New generation of robots combines AMRs and cobots Inductive charging system enables new era of robotics

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Wiferion GmbH

Wuxi InfiMotion Technology Co., Ltd.

The increasing shortage of skilled workers is intensifying the pressure to automate processes. There is a demand for flexible, cost-effective, and easy-to-implement robotic solutions such as autonomous mobile robots and collaborative robots. Mobile manipulators combine both robotic systems. Wiferion's Wireless Power Kit enables inductive charging for both systems simultaneously.

Collaborative robots (cobots) are among the most dynamically growing segments of robotics. Unlike traditional industrial robots that require shielding from the human workspace, cobots are designed for safe interaction with humans. Mobile manipulators (MoMas) combine the advantages of cobots with those of autonomous mobile robots (AMR). Here, a robotic arm is mounted on an AMR. With MoMas, even more complex handling and transport tasks can be automated with one system, without needing to install a stationary robot and a transport system with multiple AMRs. This makes these types of robots a flexible solution for a variety of applications in industry, logistics, and other areas. For the company, this means: The investment need is reduced, as not every process requires its own robot.

Automation of small parts handling

The market for mobile manipulators has been steadily growing over the past few years. Experts anticipate that this trend will continue in the coming years. This is because complex automation solutions for handling small parts in small and medium-sized series are often not cost-effective. However, in practice, the economic operation of these systems frequently fails due to energy supply issues. Since a MoMa combines two systems that were originally developed separately, the two technologies are often not considered as a holistic construct during design. In particular, the power supply proves to be a weakness. Since the battery is only designed for powering the AMR, the system's operating time decreases rapidly when an additional power consumer, the robotic arm, also needs to be powered. This means that with the current AMR battery capacities available on the market, a 24/7 operation of MoMas is hardly feasible. To bridge the downtime, additional systems must be purchased to take over tasks during charging breaks. This necessary overdimensioning of the MoMa fleet significantly complicates the economic feasibility of such systems.

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Wireless Power Kit enables complete system from AMR and cobot

It is clear that the power supply of MoMas needs to be rethought if these systems are to reach the mass market. The problem is that there is little space for additional batteries in the AMR platforms to extend operation time. Integrating them into existing AMR models is challenging. One solution is the Wireless Power Kit, a system consisting of a smart charger and smart batteries. This kit is mounted in the MoMa and efficiently powers the complete system of AMR and cobot for its tasks. The Wireless Power Kit can be equipped with a scalable number of batteries and features an inductive charging system. Depending on the energy demand, it can be flexibly sized. The energy system reliably powers both a 24-V and a 48-V robotic arm. Moreover, it is possible to equip the kit with industry-standard DC/AC converters to provide any type of industrial power supply with 230 V AC (US 220/120 V) or 400 V AC. This expands the possibilities of handling solutions that can be operated with the AMR, for instance, when a robotic arm only has an alternating current connection.

Inductive charging enables 24/7 continuous operation

In addition to a higher energy density, the Wireless Power Kit offers an inductive fast-charging system. This can increase the productivity of the MoMa by up to 32%. The wireless charging allows for automated intermediate charging of the manipulator at pick stations or workstations. With what's called In-Process Charging, the energy level of the vehicle battery remains constant. This eliminates the need for full battery discharge and the associated long charging breaks. The charging process occurs while the manipulators perform their tasks. For example, when a MoMa inserts new parts at a machine tool, it is automatically and quickly charged for the duration of the operation. At each subsequent workstation, the process repeats continuously. Even the shortest breaks of a few seconds can be used for power supply, making 24/7 continuous operation of mobile manipulators possible for the first time.

Handling tasks in critical cleanroom environments possible

Unlike traditional energy solutions with plug or sliding connections, the inductive battery charging system is a closed system without mechanical contacts. It operates without component wear and thus ensures maintenance-free continuous operation. Since no wear occurs at the charging contacts, MoMas can now also undertake handling tasks in critical cleanroom environments such as explosion-protected areas (EX), pharmaceuticals, labs, or semiconductor production for the first time. Due to the high positioning tolerance, the factory navigation accuracy of all common AMRs is sufficient to ensure the positioning of the autonomous mobile robot at the charging station. Shorts caused by inaccurate positioning, as can occur with contact chargers, are eliminated.

Already successful in application: Omron relies on Wiferion

The Wiferion system offers an elegant solution that makes MoMas economically viable. Among others, Omron relies on this system, the preferred solution provider for companies that need to quickly find a way to automate material transport tasks performed by humans. Omron provides all the key components that make up a MoMa—the AMR, the cobot, the programmable logic controller (PLC) that controls both the AMR and the cobot, as well as the various sensors and user interfaces (HMIs) that are attached to the MoMa system depending on the application. Wiferion delivers an important additional component: the power supply. The Wiferion system enables the contactless charging required by Omron’s customers in the semiconductor and cleanroom industries and also provides the extended operating time necessary in all production and storage facilities.