Integrated automation solutions for intralogistics


FT600: Automated load train

The automated load train Factory Train FT600 has been specially developed for automated logistics processes. The FT600 load train offers the same advantages as the manually operated load trains of the Factory Train range. The highlight: The lifting function is integrated in the FT600 series in the load carriers. This enables high positioning accuracy and height flexible loading and unloading at the source and destination.

Fully automated Factory Train FT600 load train for indoor and outdoor use.

Load carrier for automated loading processes


Load carriers with telescopic forks

Load carriers with telescopic forks

With the load carrier with automatically extendable telescopic forks; secured / retracted sliding load carriers such as trolleys with rollers can be automatically picked up and delivered, and pallets can also be picked up.

  • One-sided loading / unloading
  • Automatically extendable telescopic forks
  • Automated collection of trolleys / pallets

Load carriers with conveyor belt

Load carriers with conveyor belt

With the conveyor belt carrier; the load carriers can be picked up directly from powered roller conveyors or delivered to the driven roller conveyor. The pick-up and delivery height can be automatically adjusted by the lifting gear integrated in the load carrier.

  • Double-sided loading / unloading
  • Automatic transfer to driven roller conveyors
  • Collection of several loads possible

Semi-automated and fully automated operation with the FT600 load train

In intralogistics, there are various options for partially or completely automating goods flow processes.

One solution is to use partially automated systems with driver assistance systems. As a result, the FT600 load train can still be manually controlled by the operator. During the loading process, however, the driver assistance system takes over. The Factory Train load train positions itself automatically and independently at the transfer station for loading/unloading. At this point, the load train is partially automated: When approaching the transfer position, the driver activates the automation in two-handed operation. The steering is thus completely automated and the load train moves independently at a predetermined speed to the exact transfer position at the sink/source. The driver can remain on the load train during the loading process and monitor the process until it is complete. After completing the automated loading process, the driver regains control of the load train and can drive to the next station.

In the completely unmanned Factory Train FT600 load train, the tow tractor drives automatically, e.g. by means of geonavigation with laser scanners. The hall layout and the routes are measured in advance using 2D mapping and a virtual map is created. The Factory Train load train carries out the driving and navigation process as well as the entire loading and unloading process completely independently. The automated Factory Train FT600 load train always offers a manual backup solution whereby the load train can be manually driven and operated. This allows maximum flexibility when using the vehicle and means that other tasks and orders can be processed at short notice.


Automated load train for outdoor use

Driverless Factory Train load trains can not only drive automatically within production and assembly halls, but can also be driven and navigated without drivers in outdoor areas. For example, if the vehicle needs to transport materials from a hall to the adjoining hall or needs to travel longer outdoor routes spanning several hundred metres.

Automated and fully monitored: Neumaier Factory Train FT600 load train with 2 conveyor belt load carriers for outdoor use.
Automated and fully monitored: Neumaier Factory Train FT600 load train with 2 conveyor belt goods carriers for outdoor use.

Nothing is impossible with the new Factory Train FT600 load train. The FT600 can even drive automatically in outdoor areas. Automated outdoor driving has always failed due to scanner technology. However, this is now possible thanks to the new safety laser scanner from SICK AG. The SICK outdoorScan3 has been specially developed for outdoor use and works flawlessly in weather conditions including sun, rain, snow and fog, thus ensuring a stable and, above all, safe and reliable process.

SICK outdoorScan3
SICK outdoorScan3 in rain
SICK outdoorScan3 with solar radiation
SICK outdoorScan3 in snow

Personal protection system (PPS) for the entire load train

Safety is always paramount in automated processes. Load trains consist of a tow tractor with up to 5 load carriers and often reach a length of 20 metres and more. Therefore, the automated Factory Train FT600 load train is fully monitored.

In the FT600 series, not only is the tractor environment secured in the direction of travel, but the entire train is continuously and fully monitored by a personal protection system (PPS). The entire load train area from the tow tractor to the final trailer is contained in a "protection zone". Several safety scanners protect the load train, and both the direction of travel and the side areas are monitored all times. The security scanners are integrated in the tow tractor and also in each individual load carrier. The security scanners scan the environment and create a warning field and protection zone around the FT600 load train. If a person enters the area around the load train, the warning field becomes active and the load train reduces its speed. If the person then reaches the protection zone, the load train stops immediately.

When driving straight ahead, everything seems fairly straightforward. But how does the monitoring function work when cornering, when the safety scanners run the risk of identifying the train itself as an "obstacle"? Once again, the Neumaier Factory Train load train offers a solution. Thanks to innovative technology and the networking of the entire train formation to one vehicle, the load train recognises the curve radius and reacts accordingly.

In earlier automated load train models, only the towing vehicle was equipped with a PPS. As a result, only the tow tractor was monitored and not the trailers. This presented a MAJOR RISK to persons entering the load train environment.
In earlier automated load train models, only the towing vehicle was equipped with a PPS. As a result, only the tow tractor was monitored and not the trailers. This presented a MAJOR RISK to persons entering the load train environment.
The automated Factory Train load train is fully monitored. This means that the entire load train environment, from the tow tractor to the final goods carrier / trailer, is monitored at all times. This presents NO RISK to persons entering the load train environment.
The automated Factory Train load train is fully monitored. This means that the entire load train environment, from the tow tractor to the final goods carrier / trailer, is monitored at all times. This presents NO RISK to persons entering the load train environment.

Cornering speed reduction and electronic braking system

Like the manually operated Factory Train load trains, the automated Factory Train FT600 also features automatic speed reduction when cornering. In this case, the entire train formation is decelerated during cornering. The speed remains throttled until the entire train has exited the curve and is driving straight ahead. This feature, which comes as standard with all models in the Factory Train series, eliminates the whiplash effect.

Another advantage of the automated Factory Train FT600 is an electronic single-wheel brake system with ABS and emergency brake function, which can be installed on all steering axles in the train. In automation, shorter braking distances mean higher driving speeds since the train stops at a shorter distance. In addition, the load train brakes evenly and comes to a gradual and safe stop in an extended state thanks to the use of the electronic single-wheel brake system. This prevents dangerous sliding of the load carriers and ensures that the entire train formation always stays in its lane.

Safe braking and short braking distances: The optional electronic single-wheel brake system with ABS function is available for all models in the Factory Train series.

Factory Shuttle FS: The compact driverless transport system

Compact, agile and efficient. The driverless Factory Shuttles are versatile in use and, when used in combination with the Factory Train load train, create a seamless interaction between state-of-the-art and automated intralogistics. The Factory Train load trains can handle longer transport distances, both manually and automatically. For example, routes from the warehouse to the production and assembly halls. The short distances to the individual assembly and production stations are then taken over by the driverless transport shuttles. The shuttles can either travel alongside the load train and deploy at the place of use, or they can load and unload the load carriers when the load train arrives at the site.

Driverless Factory Shuttles not only standardise internal flows of goods, reducing throughput times and increasing productivity, but also increase safety. Even the driverless Factory Shuttles are equipped with security sensors with the highest security level. The environment is continuously monitored.

The Factory Shuttles come in three levels for different applications:

  • Transport shuttle (2-way technology)
  • Block storage shuttle (2-way technology)
  • 4-way shuttle

Different configurations are available for the FS Factory Shuttles. For example, a conveyor assembly for automated loading / unloading on roller conveyors. Or a structure with forks for the automated picking up of pallets.

Factory Shuttle FS
Factory Shuttle FS
Factory Shuttle FS

Automated 2-way transport shuttle

  • Transport shuttle with forks for receiving pallets
  • Electric hoist with 80-mm stroke
  • Navigation via magnetic points / RFID
  • PPS in the direction of travel
  • Mechanical PPS when reversing
  • Automatic pallet recognition at the source/sink

FL612: Automated 4-way platform stacker

Pallet handling is also automated with NI-AUTOMATION. The platform stacker is equipped with a unique 4-way steering system and offers optimum manoeuvrability when picking up / releasing the pallet unit. Thanks to the 4-way technology, the platform stacker requires little space for driving manoeuvres as it can steer and drive flexibly in all 4 directions. The platform stacker can also position itself perfectly for the loading process. Integrated scanners recognise the pallet and ensure the precise positioning on the pallet. Barcodes can also be scanned automatically.

Like the FT Factory Train automated load trains and the FS Factory Shuttle automated guided vehicle systems, the automated 4-way platform stacker also has all-round monitoring with a personal protection system (PPS). A localisation scanner navigates the vehicle using geonavigation.


Materials handling technology

A diverse range of materials handling technology is used in automation to ensure a smooth and perfectly timed flow of material. This includes roller conveyors, chain conveyors, rotary tables and storage tables, as well as special transfer stations in driverless transport systems. As a full service provider for automation solutions, Neumaier Industry also supplies complete materials handling technology and conveyor systems, which, in conjunction with the driverless transport systems such as the FT Factory Train load train and FS Factory Shuttle, guarantee high process reliability and efficient in-house material flows.


Software

The automated machines and driverless transport systems are managed and controlled by logistics software or a material flow controller. The logistics software is in turn docked on the company's internal WMS warehouse management system and connected to the ERP system. Thus, the driverless transport systems receive all relevant data and information for an efficient flow of material and goods within the company.

The driverless transport systems from Neumaier Industry can communicate with all standard logistics software solutions via an interface. If no such software or infrastructure is available in the company, we work together with well-known and specialised software manufacturers.

Do you have any questions? We will be happy to help you.

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