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Toposens launches world’s first industrial grade 3D Ultrasonic Collision Avoidance Sensor

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The Munich based high-tech startup Toposens is announcing the market launch of its first commercial Toposens 3D COLLISION AVOIDANCE SYSTEM for mobile robots based on the proprietary Toposens 3D ultrasonic echolocation technology. This represents a key milestone for the company following more than seven years of R&D and product commercialization.

Addressing the unmet need for higher safety of mobile robots in industrial settings, the Toposens 3D Ultrasonic Echolocation Sensor ECHO ONE® and Toposens PROCESSING UNIT with sophisticated filters for 3D collision avoidance is now available, having been run through rigorous commercial testing in real-life industrial scenarios with reputable mobile robotic companies. This kind of “co-developing” of a high-tech product together with leading tech firms ensures highest levels of performance for the commencing serial deployment.

Detecting the Undetectable

With the autonomous vehicle industry booming and mobile robots, such as automated forklifts, AMRs and AGVs, experiencing exponential growth levels, the safety of humans and machines is kept at the forefront of manufacturing efforts. The market has come to realize that 3D collision avoidance is a necessity, since the obligatory 2D safety LiDARs can only deliver two-dimensional data output not matching highest safety needs.

Due to their physical properties, other 3D Sensor systems, such as LiDAR or camera have limitations in their perception capabilities when for example the optical conditions in their environment are unfavorable or objects like forklift forks are close to the floor. As a result, they struggle to detect objects well enough, making them an unreliable and insufficient collision avoidance solution. In fact, the leading cause of industrial accidents in 2022 has been identified as blocked vision, and the associated costs are forecast to amount to over 2,5 Bn $ by 2025 in over 50.000 factories being equipped with mobile robots. Also, the traditional one-dimensional ultrasonic sensor does not deliver the needed data for reliable 3D collision avoidance, as it can only measure simple distance data (= time-of-flight), compared to the 3D point cloud the Toposens 3D COLLISION AVOIDANCE SYSTEM is able to generate.

Re-defining robotic safety

Trying to find a way to compensate these shortcomings and provide the market with a best-in-class 3D collision avoidance, Toposens has over the past few years been working towards a commercial version of its

3D Ultrasonic Echolocation Sensor to serve the need for a reliable mobile robot 3D collision avoidance.

Based on the principle of echolocation as seen in bats, Toposens ECHO ONE® compensates the drawbacks of optical sensors through sound-based triangulation in combination with sophisticated noise-filtering software. This in turn delivers robust 3D data output in real-time for each obstacle detected within the fully adjustable warn- and stop zones. What’s more, the zones can both be set to dynamically follow a mobile robot taking a left- or right turn and adjust to the speed of the vehicle.

The sensor sends the obtained data (echo reflections perceived by three microphones) in a 3D point cloud format to the Toposens PROCESSING UNIT which is equipped with an easy-to-configure advanced 3D collision avoidance software.

From there, depending on which 3D zone violations are detected, the Toposens PROCESSING UNIT triggers either a “slow down” or “stop” command to the mobile robot’s CPU. When no zone violations are detected, the mobile robot drives on.

Bat vision versus bad vision

“Being able to detect multiple difficult-to-detect obstacles reliably and in real-time, regardless of environmental conditions, enables us to provide next-level robotic safety for our customers. Our technology addresses the shortcomings of optical sensors, such as LiDARs, which can fail to detect floor-based objects like forklift forks on the floor, in unfavorable lighting conditions or transparent or mirrored object surfaces. Receiving data output in 3D, meaning in x, y, and z coordinates, guarantees the most reliable level of 3D collision avoidance”, says Tobias Bahnemann, CEO and Co-Founder of Toposens and continues:

“Ahead of production, we have been co-developing and testing our Toposens ECHO ONE® in pilot projects and actual real-life set-ups with renowned companies for almost two years. This has put us in a position, from which we can now offer our customers a state-of-the-art, next-level robotic safety system. With 3D collision avoidance capabilities missing in existing sensor solutions, the economic setback of damaged goods, or even expensive production stops as a consequence of undetected obstacles, can considerably limit the ROI of any mobile robot system. This highlights the necessity for mobile robots to “see” their environment using a different kind of vision technology – we call it “BAT VISION” and are delighted to now be moving on to serial production.”

Toposens is now taking orders for its first commercial version of its 3D ultrasonic collision avoidance technology with the all-new Toposens ECHO ONE®.

If you want to place an order or send an inquiry, then do not hesitate to contact us via our website or send an Email to info@toposens.com.

If you want to find out more about this industrial breakthrough and its unique capabilities, visit the company website on toposens.com/

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The most common conveyor belt issues and how to prevent them

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Like any type of machinery, conveyor belt systems will eventually experience issues from time to time. Regardless of how well-maintained conveyor belt parts are, it’s normal to face problems, especially given that conveyor belts are one of the most used pieces of equipment across many industries.

While some problems are bound to happen, there are ways to prevent common issues and extend the life of your conveyor belt parts. Below are some of the most common conveyor belt problems and ways to prevent them.

Material spillage

Material accidentally sliding, rolling, or spilling over is inevitable, especially for productions that move a lot of loose or heavy products. However, if your conveyor system is experiencing an increase in spillage incidents, it could be an issue with areas that are causing excess shaking or rattling.

To prevent material spillage, be sure to keep your conveyor system well-maintained. Clean the conveyor belt and parts regularly and consider installing impact beds.

Seized rollers

Excessive material spillage is the most common cause of seized rollers, which can halt production altogether. To prevent this downtime, we recommend installing Luff’s patented High Moisture Seal & Anti-Lock Shield. This polymer disc sits inside the end cap and remains stationary as the roller rotates around it, allowing the roller to turn freely, even with material built up between the roller end and the conveyor idler.

In addition to Luff’s High Moisture Seal & Anti-Lock Shield, you can prevent seized rollers by carefully inspecting them on a regular basis. This should be part of your regular maintenance routine.

Material blockage

Material blockage can happen due to wear and tear on the conveyor belt, sharp edges, and weak points in the system. When blockages happen, they can cause the conveyor belt to simply stop moving.

To avoid this issue, again be sure to keep a well-maintained system. Inspect your conveyor belt for any holes, weak points, and sharp edges that could potentially cause a blockage and have them repaired as soon as possible. Another solution to prevent material blockage is to install guide rollers which help reduce the chance of severe belt damage from sharp edges.

Mistracked conveyor belt

Mistracking happens when the belt moves too far to one side, which can lead to material spillage, material blockage, and cause premature wear on other conveyor belt parts. A mistracked conveyor can throw off the entire system The best way to prevent a mistracked conveyor is to have inspections and adjustments done on a regular basis. If you notice small signs of misalignment such as uneven belt wear, address them immediately before they become bigger problems.

To sum it up, some of the most seemingly small issues can turn into bigger problems that can halt operations. These common issues can be prevented and solved with simple conveyor belt parts and accessories.

Source: luffindustries.com

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Plastic load carriers from the automotive specialist

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A trouble-free internal material flow is one of the essential factors for efficient production of components for the automotive industry. Errors and faults in transport and storage systems result in time-consuming and costly interruptions. The Craemer Group, internationally established supplier to the automotive industry, is one of the leading manufacturers with large-scale production of automotive modules made of metal and large-volume load carriers made of plastic.

The automotive expertise of the Germany-based Craemer Group founded in 1912 has contributed to the development and production of injection-moulded load carriers made of sturdy plastic. Versatile plastic pallets and pallet boxes from Craemer reliably reduce downtime in the automotive and supplier industries.

Special plastic load carriers for customised applications

For more than 50 years Craemer has been developing and manufacturing durable pallets made of high-quality polyethylene (PE). Today, the extensive portfolio includes half pallets, Euro pallets and industrial pallets for a wide range of applications. One example from the company’s portfolio is the D1 plastic pallet with its 22-millimetre rim: It is specially designed for the automotive and supplier industry and ensures high load security when used with small load carriers (SLC) and clear packaging (blisters). Unlike wooden pallets, box elements can be transported precisely and safely, without strapping and fastening, thanks to the edge system.

Thanks to their 22-millimetre outer rims, the CS plastic pallets in Euro format and industrial sizes are also ideally suited for use with SLC. The ESD (electrostatic discharge) variants of the CS pallets are made of conductive material and protect sensitive components from uncontrolled electrostatic discharge. The CS pallet is optionally available with Palgrip® anti-slip runners.

The CR plastic pallets are ideal for heavy loads. They permit versatile solutions thanks to a load capacity of up to 1750 kilograms and an anti-slip coating on the deck which makes them ideal for high rack warehouses. On the other hand, Craemer H and TC pallets offer optimum hygiene conditions for sensitive processes. The H model is also available in a conductive version. The pallet portfolio for the automotive and supplier industry is complemented by the lightweight SL pallet in Euro format with an overall height of only 120 millimetres.

Safe transport and easier handling of commodities

For the automotive industry, particularly impact-resistant and splinter-proof pallet lids are an ideal complement to Craemer plastic pallets. They are available in Euro format and industrial sizes and are suitable for all common returnable containers (such as SLC). Thanks to their precise fit they close perfectly flush. Integrated strapping grooves and locks on the short sides of the lid optimise the load security of sensitive commodities. As conductive ESD variants, they also reliably protect electrostatically sensitive components from uncontrolled discharges.

Other products of the Craemer automotive range: CB pallet boxes. Thanks to the one-piece injection-moulded production and their sturdy construction, these large load carriers made from PE convince with their high resistance and long service life. They are available in Euro format and industrial sizes. In addition, they are UN-certified and thus approved for the transport and storage of hazardous goods. Precisely fitting lids are available as additional accessories. With its complete portfolio of load carriers and accessories, the Craemer Group supports safe transport and storage processes in the automotive industry.

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Mondi partners with Heiber + Schröder to launch the new high-performance machine eComPack for automated packaging of its EnvelopeMailer for eCommerce

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Heiber + Schröder’s mechanical engineering combined with Mondi’s packaging and paper expertise enables eCommerce companies to automate the erecting, filling and closing packaging process using the EnvelopeMailer solution he state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations

The state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations

The new machine perfectly complements Mondi’s universal and fully recyclable corrugated EnvelopeMailer for maximum performance

Mondi, a global leader in packaging and paper, has worked on an innovative collaboration with German machine producer Heiber + Schröder to create a high-speed automated packaging machine that meets the process, efficiency and safety requirements of eCommerce fulfilment operations. The new eComPack machine is designed for mid to large size eCommerce operations seeking efficiency and reliability. It can process up to 500 parcels per hour thanks to an automated erecting, filling and closing process.

The technological expertise of paper and board packaging automation expert Heiber + Schröder forms a perfect synergy with Mondi’s innovative packaging solutions. The resulting high-output eComPack can automatically process a wide scope of goods using one height-adaptable packaging design that is available in different sizes. The equipment stands out for its compact floor space requirement and simplicity in operation and maintenance.

In the rapidly growing world of eCommerce, the combination of an excellent paper-based product and an efficient and economic automated packaging machine is a key differentiator for our customers. The successful introduction of Mondi’s EnvelopeMailer solution increased manual packaging output by 8% compared to standard C-folder packaging. With eComPack, we are now enabling our customers to double their output and optimise packing operations in fulfilment centres handling high volumes,

Tarik Aniba, Sales & Marketing Director, Mondi Corrugated Solutions

The eCommerce market has grown significantly in recent years, accounting for approximately 20% of global retail sales in 2021¹. This means a wider variety of goods is being distributed, which increases packing complexity and requires versatile packaging solutions of different sizes and shapes. At the same time, with the rising cost of labour, the desire for packing machines in eCommerce is more prominent than ever before. To help customers tackle these challenges, eComPack provides a solution dedicated to the automated packaging of Mondi’s corrugated eCommerce solution EnvelopeMailer.

Made to safely fit single or multiple items and rectangular as well as irregular shapes up to 7 cm in height, the EnvelopeMailer’s flexibility in the fulfilment process, efficiency in handling, and economical use of material and space have made it an all-around new standard in the market since its launch in 2020.

André Garmer, Managing Director Heiber + Schröder, adds: “Together with Mondi we developed the machine in a very dynamic co-creation process. The result is a robust, user-friendly machine with top-class usability. Through clever and responsible creation, we were able to synchronise packaging design and machine functionality into a solution that offers tremendous potential if combined with the right packaging solution.”

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