Smart pallet transport systems for confined production environments

Narrow aisles, space-optimized areas, little room for error: Modern production and storage facilities make efficient use of every square meter. Employees, pallets and autonomous transport systems share the same workspaces. Nipper has optimized its driverless pallet transport vehicles with automation technology from B&R specifically for these demanding conditions – for safe, predictable and highly efficient movements with centimeter precision.

In modern production environments, people, machines and material flows come into direct contact with each other. To ensure that Nipper’s automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) can move safely at speeds of up to 1.5 m/s, they must meet the highest safety standards. The autonomous vehicles reliably detect obstacles, react to changes in real time and adapt flexibly to new layouts.

The latest generation of mobile robots for pallet handling from Nipper sets a new standard: Higher performance, centimeter accurate navigation and advanced image processing demand significantly more from automation systems. Conventional solutions often reach their limits, with new functions requiring extensive system modifications and integrations stalling, resulting in performance reserves being quickly exhausted.

"Our mobile robots operate in highly dynamic environments, but many automation systems were simply not designed to grow with our requirements," explains Ellen van Nunen, CTO of Nipper. They therefore deliberately sought an automation partner that could not only keep up, but also grow with them. They found the answer in B&R's modular and seamlessly integrated solutions. B&R's automated complete solution, consisting of control, safety systems, integrated image processing and software, ensures reliable and safe operation even where every centimeter counts.

Previously, Nipper worked with a separate PLC system and a standalone panel – a setup that reached its limits as complexity increased. Switching to the B&R Power Panel C80, which unites powerful control capability and HMI functionality in an extremely compact footprint, changed that. The integrated solution delivers significantly higher performance, reduced cabinet space and a robust design for demanding industrial environments. "The switch to the Power Panel C80 immediately showed us how much potential an integrated solution has – more performance, less effort, more future-proofing," summarizes Ellen van Nunen. With the modular B&R architecture, Nipper can now flexibly integrate new functions without having to make fundamental system changes or repeatedly redevelop processes.

To improve navigation and reliably read a wide variety of barcodes, the Nipper system was equipped with the B&R Vision system. The seamless integration of camera technology into the automation platform enables extremely short response times and particularly stable image processing directly on the controller. This allows precise results to be achieved even in challenging lighting conditions or changing environments and enables reliable operation around the clock.

The biggest advantage for Nipper lies in B&R's integrated automation technology: control, HMI, image processing and safety technology all run together in the Automation Studio engineering tool. This eliminates the need for additional tools, significantly reduces integration times, simplifies the engineering process and speeds up the implementation of adjustments. As a result, the system remains expandable and future-proof.

The B&R team from the Netherlands supported the project throughout the entire development phase with technical expertise, close personal support, and reliable service. Ms. van Nunen describes this cooperation as a decisive factor for success: "We experienced true co-creation in this project. We developed ideas together, solved challenges through direct exchange, and created solutions that go far beyond a traditional customer-supplier relationship. This type of partnership makes all the difference for us."

Nipper continues to invest in modern automation and is already working on the next stage in the development of production logistics. The company is also exploring new applications, such as integrating B&R automation technology into its stretch hooders, fully automated packaging machines that pull a stretchable film hood over palletized goods.

Because B&R’s platform is modular and scalable, expansions can be implemented without structural changes and without compromising safety or performance.

Nipper and B&R are working together to demonstrate how powerful technology and partnership-based collaboration can create a safe, flexible and fully integrated production environment.