How do KNAPP and B&R turn a futuristic intralogistics scene into real factory performance?

In a bustling production hall, autonomous shuttles, Autonomous Mobile Robots (AMR), move components with silent precision from point A to point B, while an automated small-parts storage system, Automated Storage and Retrieval System (AS/RS), boosts efficiency and optimizes space. Between machines, people and robots work side by side, showcasing state-of-the-art intralogistics now made real through the strategic partnership between KNAPP and B&R.

“Intelligent control technology and functional safety are essential to ensure smooth collaboration between machines and humans,” says Michael Humer, Country Managing Director Sales Austria, B&R. With the highly automated intralogistics solution from KNAPP, production companies use warehouse space more efficiently, manage increasingly complex orders and reduce manual processes in the long term.

Intelligent mobile robots with the X20 System
Autonomous mobile robots, known as open shuttles, handle material flow between the warehouse and production. They are controlled by the modular X20 System from B&R. “The X20 control system ensures functional safety for open shuttles and also executes all mechatronic processes,” says Franz Fasch, Head of Automation, KNAPP Industry Solutions.

Seamless integration makes the system less complex and at the same time more efficient. The modular I/O system enables a design that can be easily scaled and adapted to different sensor requirements, a decisive advantage in a dynamic production environment. In order to develop such an adaptive solution, the right engineering tool is crucial.

Optimally equipped to meet increasing requirements

“The B&R Automation Studio software provides a standardized development environment that replaces several separate tools and makes operation much easier,” continues Franz Fasch. The powerful Compact-S CPU also provides more computing power while taking up less space. This means that the open shuttles are optimally equipped to meet increasing requirements in the areas of sensor technology, safety and motion control. B&R demonstrates how this can work optimally in its own production facility in Austria.

An intralogistics solution that sets standards

The automation specialist’s new logistics system is a prime example of modern, automated production supply that can handle immense stock movements. The heart of the facility is the Evo Shuttle system from KNAPP – an automated small parts warehouse with 91,622 storage locations on four floors. 80 shuttles move on 40 levels and store containers at three different heights, some of them double-deep.

The system is supplemented by automatic stacker and destacker stations as well as intelligent conveyor technology, which ensures continuous material flow across multiple halls. The entire system is seamlessly integrated into the existing building. Extensive modifications were not necessary.

Modern and ergonomic order picking

Two key innovations have significantly improved working conditions for employees: firstly, automated Goods-to-Person picking and secondly, ergonomic Pick-it-Easy workstations. Physically strenuous manual activities have been replaced by a modern and supportive system that protects workers health and increases job satisfaction. Pick-to-Light displays and automatic supply to the workstations by the Evo Shuttle ensure intuitive processes and efficient order processing.

This means that up to 6,000 items can be processed per day, with a lower error rate thanks to an integrated software solution. “Today, automation is no longer just about efficiency – it’s about creating resilient, intelligent and human-centered production environments,” says Christian Brauneis, Managing Director, KNAPP Industry Solutions.

Continuous material flow, from goods receipt to dispatch
“From the warehouse to production and from goods receipt to delivery, automation makes it possible to react more quickly and flexibly to changes and at the same time processes become more efficient and productive,” emphasizes Humer.

The intralogistics solution from KNAPP covers the entire material flow at B&R:

Incoming goods: delivered goods are repacked into containers at ergonomic workstations and automatically transferred to the warehouse using overhead conveyor technology.
Storage: the Evo Shuttle stores the containers dynamically and in a space-optimized manner – including automatic stacking of low containers.
Picking: Ergonomic Goods-to-Person workstations enable software-supported, error-free picking of production kits and shipping orders.
Production supply: open shuttles take care of transportation to the production line – 24/7, flexibly and without additional adjustments.
Dispatch: tugger trains bring finished orders for packing and delivery.
This end-to-end automation made it possible to increase warehouse throughput by 35%.

Innovation and technology partnership characterize the cooperation between B&R and KNAPP. While KNAPP relies on B&R’s control expertise, B&R benefits from KNAPP’s comprehensive intralogistics know-how. “We have a very longstanding partnership, which is particularly evident in our autonomous transport robots,” emphasizes Brauneis. “Only with strong partners like B&R is it possible for us to develop innovative products for our customers.”

Smart manufacturing as a strategic factor for success

The combination of open shuttles with the X20 controller from B&R and the Evo Shuttle system from KNAPP creates an intelligent, scalable and future-proof production environment. Modern automation technology is thus becoming a competitive advantage and smart manufacturing a strategic factor for success.