Zeal Robotics: Spearheading the next generation of autonomous warehouses robots

From idea to functional prototype

Zeal Robotics didn’t just arrive with an idea; they had already developed a small-scale prototype. Leveraging this model, Comate looked into all options to develop a full-scale prototype that matched the requirements for speed, payload and component integration. With a lot of factors to take into account, Comate devised a plan divided into two main phases.

Phase 1: mechanics and electronics

In phase one, the emphasis was on constructing a fully operational prototype. Engineers addressed key questions: What does it need to do? What requirements should it meet? And how can we surpass what’s already out there? They mapped out the hardware architecture, defining building blocks and the way components interact. Once a functional system was outlined, they delved into a detailed engineering process - bringing the electronics and mechanics of the full-sized prototype to life.

A challenge in developing this prototype was the scanner that needed to keep a constant eye on the robot’s surroundings. To prevent collisions, it had to stop immediately if an obstruction was detected. Most generic models use two or three scanners to cover their range - but to keep costs efficient, only one scanner was used in the prototype. Through clever engineering, the Zeal Runner achieves a 270-degree view with its single scanner, all without compromising the strength of its frame.

Phase 2: integrating design

Significant progress was made in phase two, where styling was added to the new mechanics and electronics. A casing was designed using vacuum-formed shells created from molds. We identified suppliers that could scale up production using the mold-based design - making it easy to produce the casings in large quantities.

No compromises were made in developing a product that looked as good on the outside as it worked on the inside. If a mechanical or an electronical element required a design change, our team found solutions without sacrifices. The final product looks exactly as designed and maintains our high standards for both functionality and appearance.

A key focus during the design of the Zeal Runner was the close interaction between order pickers. We recognized the importance of user experience in daily operations and crafted a design that excels in usability and accessibility. Its friendly exterior with soft, rounded corners complements the inviting aesthetic while also contributing to a safe work environment.

An all-encompassing solution

Striking the perfect balance between approachability and performance, the Zeal Runner ensures smooth interaction with human operators. It outperforms other models in terms of speed and load capacity, ensuring top-notch effectiveness. With its swift movements and agile turns, it can navigate aisles as narrow as 1,25 meters with speeds up to 4,3 km/h.

The Zeal Runner sets a new standard in warehouse environments, firmly positioning Zeal Robotics ahead of its competitors. “The exceptional support of Comate Engineering & Design during this period was invaluable. It is truly appreciated”, explains Zeal Robotics co-founder Yasim Coene. “The complementary skillsets of the whole team coming together made this possible.”