Smart Connectivity for Dynamic Material Flows: FastBots Solution by SSI SCHAEFER

• FastBots Solution enables highly dynamic material flows within a minimal footprint

• System architecture combining a fleet controller, mobile robots and transfer conveyors

• Efficient transport with hourly throughput in the five‑digit range, designed for fail‑safe 24/7 operation

In many highly automated warehouses, rigid conveying system loops are increasingly reaching their limits. They are difficult to adapt to new workflows, require a significant amount of space and often lack the flexibility to adjust to changes in the product range or strong fluctuations in order volumes. Companies therefore need transport solutions that can be expanded easily, reconfigured quickly and adapted to new requirements at any time. This is precisely where the FastBots Solution from SSI SCHAEFER, a leading global provider of intralogistics solutions, comes into play. Instead of fixed transport routes, it uses a flexible, intelligently controlled fleet of mobile robots that can be scaled dynamically and integrated into existing processes without major modifications. This enables a material flow that functions reliably – even when conditions change at short notice. 

The highly dynamic FastBots Solution consists of an intelligently orchestrated fleet of mobile robots that move a wide variety of load carriers weighing up to 50 kilograms safely and gently between any type of source and destination. The technology ensures a 24/7 material flow without a single point of failure. Even during maintenance activities or the downtime of individual robots, operations continue without interruption: The fleet controller dynamically adjusts routes to maintain resilient performance and maximum system availability. It also manages the battery‑charging tasks of the energy‑efficient vehicles, which are designed for low power consumption and short charging cycles.

“The fleet controller is the core of our FastBots Solution,” explains Elmar Issing, Senior Vice President Solutions Architecture & Innovations at SSI SCHAEFER. “Based on information from the material flow system (WAMAS MFS), it plans all transport movements and controls the motion of each individual vehicle with second‑level precision.” With continuous data communication, the fleet controller optimizes the routing of the FastBots in real time and ensures collision‑free operation. The time‑based routing approach enables throughput rates in the five‑digit range per hour. In addition, the fleet controller coordinates the handovers between vehicles and conveyor technology, ensuring a smooth and highly reliable material flow.

For the loading and unloading of load carriers, the FastBots Solution – nominated for the IFOY Award – uses dedicated transfer conveyors designed for high handling performance. The fast yet gentle transfer process ensures the safe handling of a broad range of items. This stable core process works reliably at a wide variety of transfer points, including manual work stations, automated stations (such as piece picking and case picking robots) and different types of automated small parts warehouses. Building on this flexibility, the system’s modular design and standardized interfaces allow seamless integration into existing intralogistics structures and can be expanded at any time with additional vehicles or process areas. As a result, a powerful overall system emerges that significantly improves internal material flows.

In addition, the FastBots Solution has undergone extensive validation and is designed for continuous operation. In a 1.5‑year stress test – comparable to more than five years of regular operation – the robots were used intensively. Each individual unit achieved a total travel distance in the high five‑digit kilometer range. The results confirm the system’s high robustness, reliability and longevity.

“The FastBots Solution demonstrates what modern intralogistics can look like: Fast and precise transfers in the smallest of spaces, intelligent routing, maximum availability and an energy‑efficient, scalable system design,” emphasizes Elmar Issing. “With its flexibility and standardized integration, it helps companies make their logistics processes future-proof and sustainable.”