Case Study

Automated warehouse inventory via standalone drone

A design that allowed volume measurements in piles of material to be performed automatically and with high accuracy

Fertilizers

Solutions from power supply to inventory control

Project Data

MEASUREMENT

98%

accurate

The solution built reached at least 98% accuracy of the volume measured

RAPIDEZ

4 hours

to take inventory

The volumes of each box are automatically calculated after the drone's flight

SECURITY

0

employees at risk

Carrying out an inventory without exposing any worker to the risk of climbing piles

Context and Challenges

Yara Brasil Fertilizers wanted to reduce the risk of work-related accidents by carrying out the inventory work of its piles of material. In addition, the company expected to increase accuracy (in order to identify deviations) and use a solution that could be easily replicated for all its warehouses. The solution therefore had to meet the following challenges:

  1. Make the inventory of a warehouse 140m long and 30 meters wide, divided into 19 boxes with different inputs for fertilizer mixing
  2. Not to use fixed systems for the measurement because, being the aggressive environment, this would be difficult and would imply some maintenance costs
  3. Measuring batteries in various formats, with access to the batteries for measuring dimensions being hampered by walls and the risk of collapse
  4. Improve volume estimates, which until then had low accuracy

Solutions Used and Equipment Provided

We designed a solution that counted a LIDAR (laser radar) together with a position estimation algorithm, in order to increase the accuracy of the measurements of each stack.

Based on the floor plan of the warehouse and the position of the divisions of each material box, we draw up a code to automatically separate the warehouse into regions of interest (piles) and automatically calculate the volume in each region.

In order for LIDAR to reconstruct the environment completely, we developed an autonomous navigation system for a drone, based on characteristics of the environment. This way, with a flight over the warehouse we were able to assemble the warehouse in three dimensions and extract the material volume information accurately.

Experts

Digital Transformation Consultant

Reynaldo Gago

Awards

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Automated warehouse inventory via standalone drone

A design that allowed volume measurements in piles of material to be performed automatically and with high accuracy

May 4, 2021

published by

Digital Transformation Consultant

Reynaldo Gago

MEASUREMENT

98%

accurate

The solution built reached at least 98% accuracy of the volume measured

RAPIDEZ

4 hours

to take inventory

The volumes of each box are automatically calculated after the drone's flight

SECURITY

0

employees at risk

Carrying out an inventory without exposing any worker to the risk of climbing piles

Yara Brasil Fertilizers wanted to reduce the risk of work-related accidents by carrying out the inventory work of its piles of material. In addition, the company expected to increase accuracy (in order to identify deviations) and use a solution that could be easily replicated for all its warehouses. The solution therefore had to meet the following challenges:

  1. Make the inventory of a warehouse 140m long and 30 meters wide, divided into 19 boxes with different inputs for fertilizer mixing
  2. Not to use fixed systems for the measurement because, being the aggressive environment, this would be difficult and would imply some maintenance costs
  3. Measuring batteries in various formats, with access to the batteries for measuring dimensions being hampered by walls and the risk of collapse
  4. Improve volume estimates, which until then had low accuracy

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