Global Leading MNC × IPLUSMOBOT: ''Goods-to-Person'' Digital Upgrade in Chemical Warehouse

Company Overview

A global chemical manufacturer and distributor selected an aging warehouse in Australia as a pilot site for automation, aiming to achieve high-speed, highly reliable goods supply to operators within limited space while improving efficiency and complying with local safety regulations.

Pain Points and Needs:

• Strict safety requirements for the entire system.

• Worker entry into rack storage areas during AMR operation without interrupting workflow.

• Corroded and uneven flooring in an old chemical warehouse.

• High daily task volume with tight picking rhythm requirements.

• Dense layout (about 40m×40m, 330+ locations) with complex pathways.

Solutions:

EMMA 1500K Standard AMRs, the CLOUDIA System, WCS, and the client's WMS enabled a dual-safe Goods-to-Person picking system.

Project Results:

• Dual Safety Modes (High/Low Speed): High-speed mode uses safety fences coupled with a system safety controller to protect the picking system. In low-speed mode, the AMR’s onboard safety functions are activated to enable safe human-robot collaboration.

• High-Speed Operations & the E-Stop: The safety controller is deeply integrated with the client’s safety system. Inside fenced zones, each AMR can run at high speed, achieving shelf-in takt at a single picking station as fast as 18s. Via a safety wireless protocol, all AMRs support a one-button safe E-stop, meeting PL-d (ISO EN 13849-1).

• One-Click Switch to Single-Robot Safe Mode: The AMR picking system can be switched with one click to a single-robot safe mode. Each AMR then operates in a CE-compliant safety mode (ISO EN 3691-4); the safety function also attains PL-d.

• Observability & Scenario Fit: Deep integration between WCS and the client’s WMS established multi-layer tracking and exception-handling mechanisms, improving transparency and response. The system robustly supports high-density racking and Goods-to-Person scenarios, enhancing operational flexibility in real warehouse environments.

• Reliable Wireless Communication: A disruption protection mechanism was developed based on IPLUSMOBOT’s field expertise to maintain operational smoothness and safety during temporary signal loss.