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Mobile Robotics
BTicino selects ACTIVE Shuttles Donizetti & Caravaggio for Bergamo Plant Automation
To automate its intralogistics in Bergamo, Italy, BTicino relies on Bosch Rexroth's ACTIVE Shuttle autonomous mobile robot. This plug-and-go solution integrates seamlessly into the existing factory infrastructure, enhancing the internal flow of materials and goods without requiring any modifications.
“The ACTIVE shuttles,” explains Cortinovis, “not only transport the end product in our plant, but also the components that need to be delivered to the production lines. At the very moment an empty cart is set down at a defined point by the operator, a sensor transmits the call alert to ctrlX AUTOMATION, which in turn transmits it to the ACTIVE Shuttle. This picks up the empty cart and transports it to the automated warehouse, where it is loaded with components by the operating personnel. The ACTIVE Shuttle picks up the KLT and its components and transports them to the destination production line.
With almost 3,000 employees and eleven sites in Italy, BTicino, part of the Legrand Group since 1989, is one of the world leaders in digital and electrical infrastructure for buildings. The BTicino plant in Azzano San Paolo, on the outskirts of Bergamo, is well described by Paolo Cortinovis, responsible for safety and energy supply at BTicino. "The factory is organised into production cells," he explains, "where each team works on a well-defined family of products for a very specific market and follows the entire process, which begins and ends in a self-contained manner. This approach gives everyone a greater sense of responsibility and involvement in teamwork."
To optimise and further automate the plant's intralogistics, BTicino opted for two AMRs (autonomous mobile robots) from Bosch Rexroth in 2021, following a market study. "The ACTIVE Shuttle immediately proved to be the best choice for our needs, both for the ease of programming the mobile robots and for their flexibility," says Cortinovis.
Automate Economically with ACTIVE Shuttle
During initial operation, the ACTIVE Shuttle intuitively creates a map of the permitted routes in the hall. No structural measures, such as magnetic strips on the floor or reflectors, are required. The AMRs continuously optimize the centrally managed map with each trip, adding new, permanently installed obstacles as needed.
"The robots from Bosch Rexroth have integrated perfectly and quickly into the work teams. They work with and for the employees, supporting them in everyday tasks and enabling safe, effective, and successful collaboration"
Paolo Cortinovis, responsible for safety and energy supply at BTicino.
By using the AMR for dynamic production processes in the plant, it was also possible to reduce downtimes during production, as the robots are only in operation when they are actually needed for a component delivery. “We have also never had any problems with the range of the ACTIVE Shuttle, as the autonomous mobile robots return to their charging stations independently during downtimes,” adds Cortinovis.
Flexible for New Tasks with ctrlX AUTOMATION
The open automation platform ctrlX AUTOMATION from Bosch Rexroth allows the advantages of the ACTIVE Shuttle to be used faster, more efficiently and more comprehensively in the factory. ctrlX AUTOMATION enables intelligent interaction with the operating personnel and simplifies the definition of new operating locations and the removal of obsolete ones without having to reconfigure the system or change the existing software architecture.
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BTicino opts for ctrlX AUTOMATION to automate its processes.
Mauro Gervasoni, responsible for technical development and quality at the BTicino plant, quickly recognized the advantages: “We appreciate the user-friendliness of the Rexroth solution—both in terms of defining the routes and call points, as well as with regard to the ctrlX AUTOMATION system. It allows us to manage sensors that have already been installed and to integrate new ones if required. The Rexroth solution is not a rigid system that disallows further adjustments once configured. The ease with which we can change the application possibilities of the AMR is absolutely remarkable."
Another advantage of ctrlX AUTOMATION is the ability to freely choose the programming language. Users can develop customized solutions quickly and with the programming language of their choice without knowledge of the classic automation languages according to IEC 61131 or G-code. BTicino can also use the ctrlX Data Layer to collect and store information on the AMR's routes and interactions with the operators in a secure and standardized way and retrieve it at a later time.
Human-Robot Collaboration: A Successful Experiment
Donizetti and Caravaggio are the names chosen by BTicino operators for their two autonomous mobile robots, honoring the renowned local historical figures. Their interactive graphical interface, characterized by human facial expressions, has facilitated their seamless integration into the work environment. They will soon be joined by other ACTIVE Shuttle AMRs. The plan is to expand the lines serviced by these robots in the main warehouse and eventually extend to those housed in an adjacent building.
BTicino plans to further expand its fleet. The intention is to increase the lines serviced by them in the main warehouse, then extend to those housed in an adjacent building. "We will need to expand the fleet of ACTIVE Shuttles," predicts Paolo Cortinovis. "We’re waiting for new solutions to arrive on the market, offering the latest in ergonomics, security features, and footprint, which we have requested and Bosch Rexroth has promised. We’re confident that once again we’ll be on the same wavelength."
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BTicino chooses ACTIVE Shuttle to automate the operation within the warehouse.