SMART – the modular system of universal robotic stations integrated with internal transportation

Author: Grzegorz Granosik

The modular system of advanced robotic stations with integrated autonomous mobile robots for inter-station transportation was created as part of the POIR.04.01.04-00-0017/17-01 project implemented jointly by the Lodz University of Technology (leader) and Aret Company.

The system consists of stationary modules (production cells) with a special frame structure (Fig. 1) ensuring the assembly of several (created as part of the project) executive or measurement components. The main element of each cage is an industrial robot, interchangeable modules can be transport modules (conveyors), measurement modules (cameras), etc.

Fig. 1 Universal robotic module SMART (left), close up of the exemplary robot installed inside (right)

The cage structure allows it to be moved within the production hall depending on its current function (resulting from the configuration of the components). The operation and safety of each cage is managed by a PLC controller.

Separate modules are an autonomous mobile robot and a battery exchange station with their own management system, which can communicate with the cages described above, creating an integrated system of flexible robotization for the industry.

Thanks to the modular structure, the created system can be implemented in manufacturing companies or logistics centers in its entirety or individual components can be implemented in stages to make robotization easier for SMEs. The IT management system is configured appropriately to the launched hardware modules.

This technology is used on the daily basis by the integrator – Aret Company – for robotization of various industrial processes. Additionally, Lodz University of Technology has established the startup to further improve technologies related to mobile robotics.

Hetbot, founded in 2020, stands as a distinguished spin-off, born from years of in-depth technological research and development in the field of mobile robotics. Through extensive R&D projects, Hetbot has synthesized this expertise into a market-ready solution: modular mobile transport robots tailored to the diverse needs of clients (Fig. 2). These robots are designed to adapt to a wide range of kinematic configurations and can handle payloads from 100 kilograms up to 10 tons. This flexibility makes Hetbot’s offerings valuable across various industries, from warehouse logistics and industrial transport to sectors requiring highly customized automation for complex logistical processes.

Fig. 2 Autonomous mobile robot with dockable platform (left), with cabinet (right)

One of Hetbot’s defining features is its state-of-the-art power management system. In autonomous mobile robots (AMRs), downtime for recharging has long been a bottleneck, causing inefficiencies in operations. Hetbot has tackled this issue by developing an intelligent power management system that minimizes time wasted on recharging and enhances robot uptime to nearly 99%.

This system is built on a combination of smart energy management software and a battery-swapping station. Unlike traditional methods where AMRs return to a charging dock for extended periods, Hetbot’s battery-swapping system allows for automatic battery replacement, which takes approximately 2-3 minutes. This rapid process enables AMRs to resume their tasks almost immediately, dramatically reducing operational pauses. Such efficiency is unmatched in the current market, making Hetbot’s robots highly attractive for high-demand environments that rely on continuous automation.

Hetbot’s battery-swapping stations are scalable, with each station capable of servicing up to 60 robots simultaneously. This feature is particularly valuable for larger enterprises or facilities with extensive robotic fleets, as it means they don’t need to install multiple stations. Instead, a single station can handle the energy needs of a substantial fleet, optimizing both space and costs.

The power system comprises standardized hardware modules, including batteries with integrated battery management systems (BMS), power controllers, modular battery slots, and an automated battery replacement station. The entire operation is managed by proprietary software that coordinates robot movement, assigns tasks, monitors energy consumption, and schedules battery replacements. By nearly eliminating downtime for recharging, Hetbot’s solution can save hundreds of hours per day in large-scale deployments, setting a new benchmark in AMR efficiency and productivity.