Hamilton High School Robotics Team and the Ultimate Ascent

By: Matt Alderson
Lead Mentor MakeShift Robotics: FIRST Robotics Team #4039
St. Mary Catholic Secondary School

RMT Robotics Ltd.
Engineering Manager

On April 23^rd, twenty-one students from St. Mary Catholic Secondary School’s MakeShift Robotics team boarded a bus bound for St. Louis and the FIRST Robotics World Championships.  Over the next four days they would compete in a battle of technology, strategy, smarts and nerve against the top 400 high school robotics teams from across North America and around the world.  

 the team in action!

Despite being only in their second year as a team, this group of dedicated students from grades 9 to 12, along with their mentors from industry and academia were going to compete with their Frisbee-shooting-pyramid-scaling robot “Fling” in the Galileo division.  Fling was the result of six weeks of intensive effort which began in early January when this year’s game challenge “Ultimate Ascent” was announced by FIRST.  With no instructions, the students built their robot from the ground up.  With limited access to equipment they found a way to fabricate, wire, program, and test their creation.  There was not nearly enough time but they got the job done.  In fact, their robot performed well enough at Regional competitions in Waterloo and Mississauga to be ranked among the top in the world. 

“Fling” in Action

In St. Louis the team’s pit crew, scouting team, and drive team put the experience of their two Regional competitions to good use in a series of qualification matches.  In each match, three robots from each alliance try to outscore each other by shooting discs through scoring goals in either end of a 27’ by 54’ playing field.  For bonus points, the robots attempt to climb a 10 ft tall steel pyramid as the time on the clock ticks down.  Utilizing their high precision shooting system and an efficient climbing mechanism, MakeShift finished the qualification round in 23^rd place with a record of five wins, two losses and one tie. 

During alliance selections for the elimination rounds, MakeShift (team 4039) was ecstatic when they were chosen by team 1114 (Simbotics) and team 118 (The Robonauts) to round out the first seed alliance.  These three high-powered robots were the immediate favourite to win the Galileo Division and the Einstein Championship round.  MakeShift’s alliance won two of the three quarter-final matches and moved on to the semi-finals.  In front of thousands of spectators and in some of the most exciting and high-scoring matches of the whole Championship their alliance split the first two matches of the semi’s with their opposition.  In the deciding third match, some bad luck prevented MakeShift’s alliance partner from climbing to the top of the pyramid and their alliance lost (235 points to 219 points) to the alliance that would go on to win the World Championship title. 

To even be at the World Championships was quite an accomplishment and to finish so close to a world title is a testament to the team’s hard work.  The St. Mary Roboteers are inspired.  While some will be moving on to post-secondary studies in architecture, mechanical and software engineering, others can’t they wait for next season and another chance to test drive a career in technology and engineering.

 

The team would like to sincerely thank their mentors, their supportive parents and their generous sponsors: Eaton Canada, St. Mary Catholic Secondary School, the Hamilton-Wentworth Catholic District School Board, FIRST Robotics Canada, Xerox Canada, RMT Robotics, Gridpath Solutions, and FIRST Robotics team 2056.

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Founded by inventor Dean Kamen, FIRST (For Inspiration and Recognition of Science and Technology) was created to inspire young people’s interest and participation in science and technology. The FIRST Robotics Competition is an annual competition that helps students discover the rewards and excitement of science, engineering, and technology. Working with mentors, students have just six weeks to design, build, and test their robots to meet the season’s engineering challenge. Once these young inventors create the robot, their teams participate in Regional competitions that measure the effectiveness of each robot, the power of collaboration, and the determination of students. The 2012 season is expected to include 2,400 teams competing in 52 Regional events; 14 District Competitions; 1 State Championship; 1 Region Championship; and the FIRST Championship in St. Louis, April 25-28. Participants are eligible to receive nearly $14 million in scholarships from some of the finest science and engineering schools in the country.

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This year’s game “Ultimate Ascent” is played by two competing alliances.  The match begins with a fifteen-second Autonomous Period in which robots operate independently of driver inputs. Discs scored during this period are worth additional points. For the remainder of the match, drivers control robots and try to maximize their alliance score by scoring as many goals as possible. The match ends with robots attempting to climb up pyramids located near the middle of the field. Each robot earns points based on how high it climbs.

CIMCORP+ Test Cell Accelerates Development Work

Reliability, safety, usability, energy savings, and the latest technology

Lasse Salakari
Product Development Director, Cimcorp Oy

By: Lasse Salakari
Product Development Director, Cimcorp Oy

At the Cimcorp facility, work is underway on a new robot cell that will help test new robot applications and functionality.  Actually, the test cell will never be completely ready – it will be adapted and developed continuously along with new features and requirements.

The number of new technical solutions available is increasing at an accelerated pace – in automation systems the same as other sectors. When the latest technology is applied to robot systems, it also requires precision testing. Previously, automation systems supplied to customers could only be tested close to delivery, but with the new Cimcorp+ test cell, test runs can be performed as early as during the tendering, design, and manufacturing processes.

Now we are able to test the systems as realistically as possible, in conditions equivalent to the end use situations. The cell will enable the quality of our development work to improve even further and our customers will receive the latest technology after careful testing.

The new test cell has been tried out in practice too, in connection with robot systems supplied to clients. The results have been positive: new functions have been created and peripherals implemented thanks to the cell. To mention a few examples designed for the tire industry, a new type of servo gripper, a stack height measuring system, and a new cell controller have all been developed using the new test cell. The test cell also ensures the suitability of the systems for the customers’ needs.

In addition to developing and testing new features, the cell helps us to improve and update equipment and systems that we have already supplied. At the same time, the cell enables us to present the right kind of working configuration to the customers before they make their decision to procure

Safe, user-friendly solutions

The test cell project has four clear objectives: reliability, safety, usability, and the utilization of the latest technology to enhance energy savings etc. The test cell can also be used in training, for Cimcorp personnel as well as the customer’s employees.  We paid particular attention in the test cell to making the robots and peripherals safe. Ease of use was another major focal point, and we are always trying to find more user-friendly solutions in the areas of software, electrical and control technology as well as mechanics.

The cell will be used for developing and testing peripherals such as conveyors, destackers, scales, barcode readers, wireless data transmission systems, and vision systems – plus numerous other functions related to robotic systems in accordance with the current projects. The amount and proportion of conveyors in system deliveries is still on the increase. Therefore it is of vital importance to test them thoroughly. We use the cell to test for instance the functioning of different kinds of tire, stack and pallet conveyors, and their intersections. We are also going to invest in the drives and control systems of the conveyors.

Additionally, if there is a malfunction it will be possible to troubleshoot them more efficiently than before. For instance, in the case of a more infrequent malfunction we can fix cameras to monitor the robot’s performance, and we can examine the situation later from the recording.

Even though the aim of the test cell is to implement ready and effective solutions, I don’t believe the cell itself will ever be completely finished.  Continuous modifications will be made as needs arise. It will act as a framework within which we can simulate the functions that we need, regardless of the construction stage of the system on order.

Benefits of Cimcorp+ test cell in a nutshell

• Thorough testing of new technical solutions before delivery (mechanical features, electrical and control technology, software)

• Presentation of an authentic, functioning system before the procurement decision

• Testing of the applicability of the equipment for the customers’ own products

• Testing of reported faults and malfunctions on the Cimcorp premises

• Training for customer and Cimcorp personnel

STACKING UP: Reusable Totes Solve a Major Distribution Dilemma

They’re long-lasting, sturdy and chemical resistant. Europe’s answer to eliminating corrugated cardboard from the waste stream. Now it seems there’s another big benefit to using plastic totes in distribution, and this time North American manufacturers are taking notice.

For decades the single-use corrugated carton has been a mainstay of the distribution system throughout North America. As a result, each day millions of cardboard boxes are manufactured, used and recycled or thrown away. While advocates claim the cardboard container is still the best option for packaging and shipping, it’s hard to ignore the advantages of the reusable plastic tote.

In Europe, plastic containers have replaced cardboard right across industry sectors. Reusable totes are seen as a durable, environmentally conscious alternative, and the economy has adapted to ensure that value is realized over and over again, with a streamlined system for handling returnable totes from the manufacturer to the retailer and back. When plastic totes are used effectively, the return on investment is far superior to cardboard. When a plastic tote lasts 10 to 15 years, there’s considerable cost savings when you consider that you would be replacing cardboard every day.

So why haven’t more companies in North America made the switch?

One reason is that it could take months, even years, to realize those cost savings. For one thing, there’s the initial capital outlay to modify existing automation systems within the plant. The plastic totes can also be costly, particularly if they’re customized for use in specific automation needs. Then manufacturers face an uphill battle convincing marketplace partners to adapt to a new tote system. Shippers and retailers would have to adjust to new container sizes, and agree to participate in a returns program to ensure the totes get back to the manufacturer to begin the cycle again.

It’s a tough road if you decided to go it alone. In Europe, there’s the political will to make sure everyone participates, and incentives to make sure the totes are used, returned and reused.

Totes: The Answer for Automation

While socio-economic pressures forced the wide-scale adoption of plastic totes in Europe, North American manufacturers may one day be forced to do the same for a very different reason – SKU proliferation. As consumer demand and competition grow, companies are responding with an ever-widening lineup of products. To maintain inventories, they’re sending smaller shipments more often, but with more products in each – the variety in packaging creates a whole new set of distribution problems.

It’s the cardboard conundrum. Inconsistency and variety in corrugate shipping containers has long been the major stumbling block to automation in most facilities. In example after example, driven by the challenges imposed by the corrugate shipping container, companies considering process automation in their warehouses have been either stymied by the cost and complexity of the solution, or in many cases, have been told that automation is not even possible. Some companies see manual handling as the only alternative. But with growing throughput and the steep price of labour, many companies are turning to third party logistics firms to try and find a cost effective distribution solution.  That’s really just a short-term fix. As labour costs continue to increase, the annual investment for these subcontracts also continues to rise.

As it turns out, the EU may already have the answer. While the Europeans celebrate the environmental benefits of the reusable tote, there are some big automation benefits to using plastic containers.

For one thing, they’re built to be stacked, and therefore inherently consistent in sizing, unlike cardboard containers.  Corrugate encourages a high variety of packaging whereas returnable containers mean more consistency. The totes eliminate many of the technical challenges associated with dimensional inconsistency and material porosity.  In short, dunnage is far superior to corrugated cartons, when it comes to the speed and accuracy of automation.

It’s that kind of performance that manufacturers count on to ensure a solid return on investment from warehouse automation, and the reason RMT Robotics is a strong proponent of reusable totes

Cardboard manufacturers insist their product can be built in standardized sizes, and reinforced for strength. But are they strong enough to compete with plastic? Not a chance. There are limits to the design flexibility of cardboard, and our research indicates that cartons are much more prone to getting crushed. And, have you ever seen what happens to a cardboard box when it gets wet? Used roughly, a plastic container will last a minimum of 5 years. With some care in the way they’re used, moved and stored, a plastic tote can be in service for up to 15 years. That’s something you won’t find with cardboard.

Strength and durability aside, the plastic tote still has a long, arduous journey to make in convincing North American manufacturers there’s more than an environmental benefit to thinking outside the cardboard box.

We’d like to hear from you! Tell us your thoughts on the long-running debate over the use of corrugated cardboard containers and whether plastic totes make more sense.

Making A Difference Through Mentoring

As a company that relies upon the high level of expertise of our engineers to produce state-of-the-art robotic solutions, RMT is very aware of the importance of mentoring and encouraging the next generation of scientists, engineers and technologists. That’s why RMT is proud to be a part of the FIRST®  Lego®  League (F.L.L) and FIRST® Robotics Competitions (FRC).

Inspiration and Recognition of Science and Technology (FIRST) is dedicated to inspiring young people to be leaders in science and technology through hands-on, team-based robotics challenges. In addition to teaching students job skills in the fields of design, programming, web development, finance, marketing and project management, mentors to FIRST teams serve as positive role models who inspire values of teamwork, self-starting and time management.

FIRST competitions are a great way to spark interest in the fields of engineering, science and technology among students and RMT is proud to be a part of these innovative and exciting programs to support the next generation of robotics engineers. Here’s what students have to say about the impact of the program:

RMT employees have been involved with a variety of age-specific FIRST robotics teams for the past five years –even starting a new team in 2011. Mentoring programs include:

• Elementary School: RMT Engineering Manager Matt Alderson coaches F.L.L team GARF, eight students from Guardian Angels Catholic Elementary School building robots out of Lego pieces while researching real-life engineering problems surrounding food safety. Alderson and GARF are also serving as mentors to a new F.L.L. team at St. Thomas School in Waterdown, Ontario.

• High School: Alderson started a new team in 2011, “MakeShift Robotics” team 4039, at St. Mary Catholic Secondary School in Dundas, Ontario. Made up of 20 students, “MakeShift Robotics” RMT employees, including RMT Manager of Operations Rick Trigatti, have assisted and mentored FIRST team 2056 from Stoney Creek, and new team 4022 from Waterdown High School in Ontario. Billed by FIRST as the “varsity sport for the mind,” high school teams and their mentors spend six weeks building robots from an unassembled kit of parts, program those robots and compete in regional and national competitions throughout the season.

We are proud and excited to report that MakeShift Robotics and their robot “Fling” recently competed on January 5^th that resulted in a coveted Judge’s Award and ended the event with an offensive power ranking of 15^th in the world.

Video from one of MakeShift‘s Regional matches can be found here.

Despite not qualifying for World’s by winning their Regional events in Waterloo or Toronto, the people at FIRST headquarters recognized the team’s passion and the competitiveness of our robot “Fling”.  As such, they made a special invitation to MakeShift to compete in the FIRST World Championships to be held later this month in St. Louis, Missouri.  Our team will compete against the top high school teams from around the world in a frisbee-tossing-pyramid-climbing game called Ultimate Ascent.

If you’re interested, the event can be viewed live on April 26 and 27 at http://www.nasa.gov/multimedia/nasatv/index.html.

Go Team Go!!

To learn more about First Robotics visit their website at :

Canada:http://www.firstroboticscanada.org/main/

USA: http://www.usfirst.org/

No man is an island

Not every area of grocery distribution is suited to full automation and, in these scenarios, ‘islands’ of automation – fully integrated with the surrounding manual operations – may enable clients to achieve maximum benefit for minimum investment.

Distribution centers that have both crate handling and other operations – such as manual order picking, handling of whole pallets or handling of items in cardboard cases – use a combination of logistics technologies. In these applications where full automation is generally not feasible due to cost or complexity, Cimcorp’s ‘order processing islands’ can be a highly effective solution for automating the handling of full crates.

For example, the islands are ideal for the handling of fresh fruit and vegetables within the distribution networks of large grocery retailers.

Efficient robotics

Cimcorp’s order processing islands for plastic crates feature overhead gantry robots that combine buffer storage and order picking functions into one flexible operation. With the gantry design being modular and able to accommodate any number of robots, the system can handle large volumes with ease, as well as several different types and sizes of crate. The island prepares orders for retail stores – with product pallets going in and customer pallets coming out – enabling goods to be transported to the supermarkets without the need for any further processing. The unmanned island is totally self-sufficient, taking care of goods reception, put-away, location of stored items, retrieval planning, picking of crates, sorting and assembly of crates into discrete orders, and loading of the orders onto transport units ready for delivery.

Clear Benefits

The order processing islands secure a number of key advantages. Picking rules can be customized – such as placing heavy products at the bottom of crate stacks, arranging crates into product families, splitting transport units into temperature-specific groups and taking into account expiry date or production batch. This enables consistent implementation of retailer preferences and thereby facilitates handling within the supermarkets. Full tracking and tracing are possible, with all goods movements being communicated to the host system without the need for barcodes or RFID tags. Furthermore, as the crates are stored on the floor without racking, the robots are able to empty the entire floor area fully automatically for easy cleaning to meet the demanding hygiene standards required in the food industry. Finally, with the island surrounded by safety fencing to prevent unauthorized access, security is also enhanced.

 Click to see automation in action on our YouTube page!

Cincorp is excited to announce that Spanish grocery giant, Eroski has recently placed a second order for Cimcorp’s order processing island solution.

Seeing the Forest and the Trees

A New Perspective on Automation in Final Finish
By Don Heelis, Global Sales Manager-Tire Systems for RMT Robotics

When you can’t see the forest for the trees, the best way to solve the problem is often to step back and try to see the larger picture. Its sage advice and a philosophy smart tire makers are adopting as they look for new, innovative ways to streamline the costly processes in final finish sequencing.

Without exception, every tire plant in the world requires tires to pass through the finishing processes quickly, efficiently, and accurately. That being said, even in this modern age, many tire plants continue to rely on armies of tire handlers and fork truck drivers to keep tires flowing through the final finish operation (grinding, balance and uniformity). Although manual handling offers considerable operational flexibility, the ever increasing cost of labor, combined with continued pressure to move towards a Lean Manufacturing environment (100% inspection, reduced WIP inventories, and zero processing errors) makes most tire companies anxious to automate tire handling through the final finish process.

Naturally, most initial automated concepts for tire handling are conveyor-based solutions. Although workable, it becomes rapidly apparent that these conveyor solutions can be complicated and operationally intolerant, usually necessitating machine modernization as part of the project (random in-feed versus batch processing) as well as imposing unidirectional tire flow on the operation, making it difficult to automatically process tires multiple times if necessary. Seemingly, with few other options available, many manufacturers are unwilling to accept the operational limitations of a conveyor-based solution, and reluctantly choose to continue to handle tires manually through the final finish process.

A View Through the Forest

Stepping back to analyze the problem and plot a solution with conventional technology, RMT Robotics has addressed the challenges faced by tire manufacturers worldwide and created an end-to-end automated system for final finish buffering and delivery.

We encourage our customers to take a wider approach to automation. Our gantries are already being used in many tire plants to sort and palletize product discharged from final finish. We thought about it and said: why not move the automated solution upstream and employ the gantries to first buffer and sequence tires through final finish, before palletizing?

The wheels on the cargo round and round.

The more conventional layout approach to this automation process is sequential, where tires move directly from buffer to final finish automation and then to palletizing – in a single direction of flow. In theory, this should work and certainly this sequential approach simplifies the automation; however, in practice, this solution is operationally restricting.  It’s been RMT’s experience that most final finish operations are dynamic, not sequential, where percentages of tires (as much as 30%) may visit and revisit the final finish process several times before they are released to pallet and warehouse. That is why RMT’s approach to the automated handling solution encourages and supports this re-circulating approach to tire flow.

Preserving Legacy Saves on the Bottom Line

This re-circulating approach to the automated handling of tires in final finish provides the mandatory flexibility and added cost savings needed to justify the modernization project. Aside from the obvious labor and space savings, this “any tire – in any quantity – to any machine – at any time” controlled approach to the solution provides a dramatic improvement in the effectiveness of the existing final finish production machines. Reduced lost time to changeover provided by the consistent flow of product in optimized batch quantities, has, in several cases, increased the efficiency of the aging uniformity and final finish machines by 30-50%.

In one particular example, initial plans to replace and add uniformity machines as a function of the final finish modernization project were abandoned after RMT conclusively demonstrated to the client the stabilizing effect of the buffering automation on the production machinery. In the end, the automated installation occupied less space than the manual operation while moving more products, in less time, through the legacy uniformity machines. Performing this unprecedented task with virtually no labor costs in its operation was the icing on the cake!

 Bringing “Lean Manufacturing” to the Final Finish Operation

Where materials handlers once juggled pallet-load quantities to try and feed the final finish operation, robotic gantry-based buffering solutions now release product in precise batch quantities, on demand, to the production equipment. Rather than forcing a change in the operation by regimenting the flow of tires in a unidirectional process, the RMT re-circulating approach to the solution provides the mandatory flexibility needed by the operation, which optimizes operational flexibility and amplifies the payback of the modernization project.

How U.S. traceability legislation impacts food supply chain

Guest submission by:
Bruce Olive
CEO and Co-founder
Koroberi, Integrated B2B Marketing

FDA Food Safety Modernization Act ushers in new requirements and responsibilities

In December 2010, the United States Senate passed the Food Safety Modernization Act (FSMA) in response to a growing public concern about the integrity of both local and imported food supplies and the inability of officials to trace the sources of many tainted foods. As those involved in the food chain begin to examine the impact of the new legislation, one requirement in particular is striking:

“The Secretary [is required] to establish a product tracing system to track and trace food that is in the United States or offered for import into the United States.” (FSMA δ 204 (c))

The regulations contained in the Act target both local suppliers and importers, name of the companies shipping and transporting the case can be captured with a bar code scanner. Similarly, upon shipment, information regarding product type, lot number, dispatch details and the name of the transportation supplier must be captured and recorded. This information is vital, Ratliff says, for meeting the new requirement of and consequences for non-compliance are severe. According to Dr. Don Ratliff, Regents and UPS Professor and Research Director – Georgia Tech Integrated Food Chain Center, any organization involved in the importation, manufacturing, production, storage, transportation and sale of food needs to understand the consequences, requirements and cost of compliance of the bill.

Defining traceability in black and white

The new Act will most likely mean an increased burden on the bar code. Every shipment will likely carry a bar code label that tracks at the case level where a product is produced and who produced it, as well as a unique lot number and content description. Ratliff believes that a logistically viable solution is a dynamic tracking scenario.

When product is received, information regarding product type, lot number and the tracing the product one forward and one back in each point of the supply chain.  In addition, manufacturers, distributors and importers will need to record processing, handling, storage and transportation details for internal record keeping. Fresh produce will only require straightforward traceback methods because the supply chain is reasonably linear, but food processors and cold chain operations will need more complex traceback methods.

Global standards

From bread to strawberries, to cans of soup to bottled fruit drinks, every food product is different in terms of origin, ingredients, storage, transport and shelf life.  Moreover, these products are referenced differently as they pass language, culture and brand barriers.

The success of a track and trace system, however, relies on a standardization of these diverse product descriptions that can be translated into associated database codes. Now is the time to confront and find a solution to standardize product labeling, says Ratliff. Without a global set of standards, the challenge of developing and maintaining a centralized traceability database may well become insurmountable.

Real-time data capture and automation

The most practical way to handle the required volume of transactions is to automate the capture and upload of tracking data to an online database. A web-based system would allow FDA officials to manage recalls more efficiently while storing data securely. However, such a database does not currently exist, and there are many issues regarding who would be responsible for storage and management of the data, pricing, etc. that need to be resolved.

A silver lining

Ratliff predicts that, while there may be a significant cost burden on the food chain in order to ensure compliance with the new Act, there are some potential benefits to both consumers as well as suppliers. For consumers, the visibility and accountability in the food chain should result in enhanced food quality and freshness with less risk of contamination.

Supermarkets, food retailers and food suppliers can all benefit from increased sell life of products, better order management, fewer rejected loads, less waste because of better handling and a quicker and more efficient way to identify where failure points occur.

He emphasizes that, in order to receive the advantages of increased visibility, it is essential that the tracking data be standardized at the case level and that it be shared across the entire supply chain.

While many procedures are yet to be specified, the law provides for pilot studies to be undertaken by industry groups and organizations, like Georgia Tech’s Integrated Food Chain Center, to evaluate potential tracking systems and make recommendations. Ratliff advises that food suppliers around the world should become proactive in determining how to get ahead of the regulations by meeting best practices rather than waiting for mandates.

Together, automation and standardization will make it easier for food and beverage suppliers worldwide to comply with the Food Safety Modernization Act and benefit from all that comes from tighter control of inventory.

Cimcorp Announcement

Cimcorp to implement its robots in a new logistics facility for Mercadona

Mercadona, the Spanish retail company, has commissioned Cimcorp to design and implement a fully automated order picking system for fresh produce. Cimcorp will also take care of the material flow control.

Mercadona is investing in new warehouse technology at its Guadix distribution centre. To achieve improved efficiency and customer satisfaction, Mercadona has awarded Cimcorp the contract to supply the automation system for full-crate picking.

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