Dark Warehouse: What's behind it? (Part 2)

Robots in the spotlight, everything else in the dark.

What is a dark warehouse?
The term initially sounds like science fiction or Darth Vader's "house". However, "dark" in this case does not mean dark, but that such a warehouse actually manages without lighting and works completely in the dark. People need light, machines do not. All processes run automatically: from incoming goods inspection to storage and dispatch. People only intervene in the event of maintenance or malfunctions.

Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) move independently through the halls. Conveyor technology or conveyor systems connect machines and storage areas for continuous material flows. For example, they transfer pallets from a machine to a conveyor line and transport them to a transfer point. The systems are precisely coordinated with each other. They communicate directly with other systems. Tasks that used to be carried out by people are now performed by cameras, sensors and algorithms.

Origin of the idea
The first automated high-bay warehouses were created in the 1960s. Simple warehouse management systems followed in the 1970s. But without sensors and sufficient computing power, people remained indispensable. Further automated solutions were added from the 1980s onwards. Development accelerated with Industry 4.0, big data, machine learning and robotics. Today, companies are already operating fully automated warehouses with almost no lighting or personnel. They come very close to the dark warehouse principle. What sounded like a dream of the future a few years ago is now a reality in pilot projects and in some sectors.

Technologies in the Dark Warehouse

The functioning of a dark warehouse is based on the interaction of various key technologies. However, this requires clear process definitions, clean workflows, well thought-out layouts and the right software:

1. robot technology
Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) move pallets, pallet cages, crates and cartons through the halls.

• AGVs follow fixed routes through a warehouse or production hall and are guided by rails, magnetic strips or lasers.
• AMRs navigate flexibly using digital maps, sensors and cameras. They recognize obstacles and independently choose the best route.

Typical tasks of AGVs:

• Move pallets from goods inwards to the warehouse.
• Transport material between warehouse and production/assembly.
• Drive finished goods to dispatch.

Stationary robotic arms perform tasks that require precision and repetition. They relieve people of heavy physical work. During order picking, for example, they pick items from an AutoStore bin and place them in the correct target container. They can also assemble sets/kits independently.

2. automated conveyor technology
Automated conveyor technology includes all systems that independently transport cartons, containers, crates or pallets from A to B. It ensures a smooth flow of materials between storage areas and machines in intralogistics. It ensures a smooth flow of materials between the storage areas and machines in intralogistics. This includes conveyor belts such as roller conveyors, belt, chain or screw conveyors. Various sorting systems such as the crossbelt sorter (cross goods sorting solution) complement these systems.

Telescopic conveyors are also used. They consist of movable elements that can be extended and retracted like a telescope to bridge different lengths. It is a conveyor system with which goods can be flexibly loaded and unloaded into vehicles, trailers or containers. Automated conveyor technology also includes turntables and carousel systems.

3. automated storage and retrieval systems (AS/RS)
Automated systems store goods in a space-saving and efficient manner. These include Autostore, mobile racking, shuttle systems, storage lifts and high-bay warehouses.

1. AutoStore: Robots drive on an aluminum grid, dig out the required bins and bring them to the port.
2. Mobile shelving: The shelves stand on rails. They can be moved sideways so that only one aisle is open at a time.
3. Shuttle system: Small trolleys move along the shelf levels. They transport containers to a lift that brings them quickly to the picking point.
4. Storage lift: These systems resemble an oversized pharmacy cabinet. They automatically move trays to the removal opening.
5. High-bay warehouse with storage and retrieval machines: narrow vehicles run on rails. They store and retrieve pallets over several floors.

4. warehouse management system (WMS)
A WMS is the digital brain of the warehouse. It controls and monitors processes from goods receipt and storage bin management through to picking and dispatch. The WMS coordinates the robots and transport orders. It keeps stock levels up to date at all times, makes optimum use of storage space for putaway and ensures smooth processes. In short, the WMS turns the Dark Warehouse into a perfectly automated warehouse in which everything works together efficiently, precisely and reliably.

Note: In addition to the WMS, a WCS (Warehouse Control System) and a WES (Warehouse Execution System) can also be helpful.

5. data science and artificial intelligence (AI)
AI algorithms analyse data from the WMS, calculate the optimal storage locations, forecast requirements, minimize empty runs and optimize routes. More on "Warehouse Healing" strategy for an intelligent warehouse: reducing travel times through data science and AI."

6. automated packaging systems
After picking by a picking robot, machines take over the packaging process. Carton erectors, carton sealers (adhesive tape or a hot-melt adhesive) and shipping label printers are used for this. For additional stability, strapping machines place plastic straps around the cartons. However, there are also fully automated volume reduction and sealing machines that are sensor-controlled and adapt each package individually to the actual contents.

Palletizers(palletizing robots at HAKRO) stack the cartons precisely onto pallets. Pallet wrappers then secure them with stretch film. Labelling machines apply barcodes, addresses or logos and make each consignment clearly identifiable. If goods need to be unloaded from a pallet, the depalletizer takes over this step. Equipped with cameras and sensors, they also check the quality. They detect damaged goods or incorrect labels and sort out faulty pallets. The result is an end-to-end automated packaging process.

7. sensors and Internet of Things (IoT)
Sensors continuously collect data in the warehouse. They record goods, containers, machines, vehicles and every movement. Sensors prevent collisions, monitor the climatic conditions of sensitive goods and record energy consumption. This information reaches the WMS in real time via the Internet of Things (IoT). The data obtained forms the basis for analysis and optimization. This keeps processes stable and reduces downtime. They also check the condition of systems and report maintenance requirements in good time. Keyword: predictive maintenance (point 8). In short: sensors provide data. IoT networks them.

8. predictive maintenance
AI systems and sensors recognize early on when machines or robots need maintenance. Sensors record data such as temperature, vibration or power consumption. Algorithms evaluate this data and recognize patterns that indicate wear. They then determine the best time for maintenance. Instead of adhering to fixed intervals or waiting for a defect, the system reacts proactively. This has clear advantages for intralogistics: Systems run more reliably, downtimes are shortened and unnecessary maintenance is eliminated. This saves costs and conserves resources. Conveyor technology, storage and retrieval machines and autonomous vehicles work more efficiently in day-to-day warehouse operations.

"A dark warehouse is not just a warehouse without light, but consists of highly complex, networked and digital intralogistics."

Reasons for a dark warehouse?‍

1. E-commerce boom: millions of orders have to be processed in record time.
2. Fewer and fewer people are opting for shift work or monotonous activities.
3. Companies are looking for ways to speed up processes and reduce costs.
4. The technologies are ready for the market: robots, AI and automation are not only technically reliable, they are also economically viable.

This is how the warehouse changes:

• From a people-centered working environment to a technically driven network.
• From reactive problem solving in everyday life to predictive control through data.
• From limited availability to continuous operation without interruptions.

In the third part, we look at the manual warehouse - the status quo of intralogistics. From classic processes with employees, forklift trucks and paper. And we ask ourselves: can the manual warehouse really still score over a dark warehouse?

Click here for Part 1 - Dark Warehouse: Is this the future of the warehouse?