FEATURE Automated warehousing
The foundation of warehouse automation
W
ith continued e-commerce growth, companies must continually re-evaluate their inventory needs so they can
reliably fulfi ll orders quickly and effi ciently. In this eff ort, automation is a crucial element in material handling effi ciency that is becoming the standard in modern logistics. “Today, the large companies are incorporating automated storage and retrieval systems, autonomous robotic devices and AGVs. Smaller companies are using a scaled-down approach, such as shuttles or conveyors, to increase operational effi ciency,” says Bryan Gauger, president of Cisco-Eagle, a full-service, material handling systems integrator that provides warehouse design, equipment and project management services. These automated systems pick products, totes or pallets from increasingly large storage locations and move them to designated areas for shipping and fulfi llment. In contrast to labour-intensive, manual material handling, automation can signifi cantly improve productivity, accuracy and consistency whilst reducing operational costs. However, it is essential to understand the indispensable role racking plays in enabling warehouse automation. “In any automated warehouse system, the rack is foundational. It is the base of the system, where all inventory is stored and retrieved, so it plays an integral role in the automated system’s overall reliability, productivity and effi ciency,” says Gauger. He adds that the rack structure must
provide a controlled environment in which every storage location is uniquely identifi ed, tracked and integrated with the automated warehouse system. The trend toward increased warehouse storage density, along with automation, is only intensifying the need for greater precision and tighter tolerances.
Critical rack tolerances When the warehouse rack systems used with automation are over 10m high, any out-of-tolerance dimension can quickly cause errors or damage when automated systems attempt to store or retrieve items.
36 October 2023 | Automation
By Del Williams, technical writer based in Torrance, California, the US
Gauger says rack tolerances in the range of only one to two-millimeter variations have become essential today. Extremely tight rack tolerances are
required to use automatic storage and retreival systems (ASRS), which combine conveyors, shuttles and robotic pieces with software-controlled systems to automate the movement of goods from multiple levels within a storage facility. Because of this, rack tolerances must be precise for the ASRSs’ computer-controlled storage and retrieval system to work properly. If tolerances are off , loads can deposit into a beam, upright or in the wrong location. Gauger points out that automated crane systems, commonly integrated with ASRS, must be paired with racking of remarkably precise construction to function reliably. “When a crane expects a pallet to be at a
defi ned location and height, there is little room for error,” explains Gauger. “If the rack doesn’t meet required tolerances or FEM Racking and Shelving specifi cations, every rack location has to be mapped into the crane’s control system row by row, which is very time-consuming. To avoid having to map the entire system, the rack must be constructed to very tight tolerances.” The construction of the rack also plays an important role. Although Cisco-Eagle can work with any vendor, Gauger often opts to partner with a preferred rack supplier, Stevens Point, US-based Steel King Industries, an OEM that provides
pallet rack and custom storage solutions nationally.
“The construction of the rack is very important, including where the holes are punched, how it is welded together, the straightness of the beams and the squareness of the uprights,” says Gauger, adding the two companies have collaborated for over 30 years.
Engineered solutions Although Cisco-Eagle has its own engineers, it fi nds that working with a supplier like Steel King facilitates integration with automation because the OEM’s engineers provide valuable assistance with rack design. The collaboration enables full integration of AGV use and the optimisation of extremely space-effi cient high-density pallet rack designs, such as pallet fl ow and pushback. As the rack becomes larger and more complex, it must be designed for the specifi c location, any expected seismic activity and required loads. When this is necessary, according to Cisco-Eagle’s Gauger, engineers at a rack supplier like Steel King help expedite the process of meeting code.
“In our experience, they make some of the best-engineered racks in the industry. Rack quality and consistency are important considerations in integrating automation and prolonging its usable life, which is why they are our preferred supplier,” says Gauger.
automationmagazine.co.uk
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