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AS/RS System Components

Brandon Doyle October 30, 2009. AS/RS System Components . What is the Current Stat e ?. Definition of AS/RS:

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AS/RS System Components

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  1. Brandon Doyle October 30, 2009 AS/RS System Components

  2. What is the Current State? Definition of AS/RS: • An Automated Storage and Retrieval System (AS/RS) is a mechanical system comprising of the Storage and Retrieval machine (SR), storage area, and controlling system that allows rapid and accurate high-density storage of industrial and consumer items of many different configurations ranging from automobiles to movies to blood samples. RedBox is an AS/RS!

  3. Where is AS/RS Used? • Unit Load • Mini Load This is a tiny list! There are thousands more.

  4. So what does an AS/RS consist of? • Runway or rail • End Stop • Top Guide-rail • Driveline and motors • Sensors • Controls • Safety equipment Mini Load AS/RS

  5. Wheels, Load Table, Sensors and Rail System Load Table and Rail; Note load indicators Rail System; Note wheel sensor

  6. Safety Brake Speed Governor Safety Equipment Fall Brake

  7. Two Types of AS/RS programming: One Command Operation VS Dual Command Operation

  8. Controllers: Onboard IO Controller • IPC control with standard industrial PC or PLC • Uniform control architecture for all S/R machines models • Consistent use of bus communication technologies • Control platform is open architecture (Allen-Bradley Controllogix or Siemens S7)

  9. Sensors and other required support: • Laser, IR, and Optical sensors • Absolute linear encoding systems • Standard maintenance-free asynchronous (AC) motors with frequency converters (integrated position regulation)

  10. Some common Specs: • Absolute encoding using laser or tooth belt is used for all positioning, both vertical and horizontal. • Up to 22,000 lb. load capacity (for large Unit Load AS/RS) • Dual motors on each axis of motion for speed and reliability • Vertical carriage moved by 2 triple roller chains • Some moved by belt or winch • Dual mast design – no cantilevered loads • Most are single mast design • Operates between -30F to ambient conditions • Maximum Vertical speed of up to 400 ft./min. • Horizontal acceleration: Up to 3.28 ft./sec.² • Maximum Horizontal speeds of up to 1,312 ft./min. • Can be up to 165 ft. tall (for large Unit Load AS/RS) • Maximum load transfer speed as fast as 1.5 seconds (for Mini Load AS/RS)

  11. Unit Load AS/RS Unit Load AS/RS • Unit load AS/RS configurations can be extremely large: • Some on the order of 165 feet tall. • Entire building structure can be comprised of the rack system. • Very heavy and large items can be stored and retrieved, on the order of 22,000 lbs. Up to165 ft.

  12. Storing or Retrieving a Load 1 Load table empty, program advances chain drive. Load enters table area. Laser (or IR or Optical) sensor determines load seated properly. 2 3

  13. Videos • http://www.youtube.com/watch?v=kdVet_UOx30 • http://www.youtube.com/watch?v=bBJnO7S9hWw • http://www.daifukuamerica.com/video/products/Synchronized_System_A_Daifuku_Innovation

  14. Rules and Limitations: • Bin size constraints • Load capability of crane • Building size limitations (height especially) • Number of transactions required per hour • Maintenance and downtime • Feasibility and rate of return on investment • Load Bulge • Load Shingling • Load Stacking Pattern(s) • Use of Slip Sheets • Positioning Accuracy: +/- 0.1 inch

  15. Vendors

  16. Existing Standards(per the Material Handling Industry of America) • Meets Safety Codes: ANSI B30.13, NEC, OSHA, NEMA, and JIC • American National Standards Institute (ANSI B30.13) • American Gear Manufacturers Association (AGMA) • American Welding Society (AWS) • Anti-Friction Bearing Manufacturers Association • National Electric Code (NEC) • National Electrical Manufacturers Association (NEMA) • Occupational Safety and Health Act (OSHA), Federal (Public Law 91-596) and its regulations in effect at the time the S/R machines are being designed and built. • Uniform Building Code (UBC), if and as applicable • Building Official Code Administrator (BOCA), if and as applicable • Southern Building Code Congress International (SBCCI), if and as applicable • Rack Manufacturers Institute, (RMI) Safety Practices ANSI MH 16.2 • Rack Manufacturers Institute, (RMI) Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks • Association of Iron & Steel Institute (AISI) & American Institute of Steel Construction (AISC) Design Manuals if and as applicable • Owner’s Standards or special terms and conditions - Reference number(s) & date(s) • National Fire Protection Association (NFPA) 231-C • All wiring shall be sized and installed in accordance with the National Electric Code (NEC)

  17. Costs • Typical costs range from $800,000 to $1,200,000 per aisle (for a 100’ long by 50’ tall aisle). Large industries can have upwards of 15 aisles 150’ or more long and up to 165’ tall. • Maintenance can run around $12,000 a year per aisle.

  18. Consumer Application Consumer RedBox DVD Storage

  19. Summary AS/RS has revolutionized warehousing and logistics of almost every type. This technology has allowed lean manufacturing and industry practices to become more prevalent throughout the world and will continue to improve how things are moved and stored.

  20. References • http://www.daifukuamerica.com • http://www.bastiansolutions.com • http://www.hksystems.com • http://www.jervisbwebb.com • http://www.ciscoeagle.com • http://www.us.viastore.com • http://www.westfaliausa.com • http://www.accalon.com

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