Distribution
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How to design the power distribution infrastructure for your distribution and fulfilment centre
By Daniel König, strategic business development, TE Connectivity T
oday’s most progressive warehouses rely on electric forklifts and automated vehicles to automate the transportation, organisation, and delivery of goods and materials within the facility. From automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) to electric forklifts and automatic storage retrieval systems (ASRS), these new solutions are significantly improving productivity and efficiency for the rapidly growing e-commerce markets. But these systems need fast and reliable power distribution to work optimally. It all comes down to the warehouse’s internal power infrastructure and the framework that supports it all: rugged connections that can reliably transmit a lot of power every hour of every day. The electric powertrains that enable vehicle automation rely on smart battery technology, fast recharge capabilities, and opportunistic charging that allows the vehicles to recharge whenever they need to without human intervention. Until now, that hasn’t been easy to achieve in the warehouse environment.
The evolution of power distribution in warehouses
When fulfilment and distribution centres were first built, the highest priority was on maximising space. The greater the warehouse’s capacity, the more items could be stored and shipped to customers. Figuring out the proper power distribution tended to be simpler overall – there was a “charging room” set aside for charging big equipment like electric forklifts, and there were necessary power supplies installed for lights and other equipment.
That changed once the automation revolution began. As automated vehicles, digital warehouse management systems, sensor technology and other tech innovations became more common, the discussion about power distribution became much more complex. Now power needed to be accessible almost anywhere on the warehouse floor
28 March 2023
and in a variety of applications with multiple access points and current and voltage requirements. Power distribution was no longer just about providing enough power to the right spot, it was also about high-speed data communication and maximal charging speed as well.
For example, consider the diverse power distribution needs of these two units found in most modern warehouses: ● Control cabinets: These electrical devices that monitor, control, or change the flow of electricity through a device are housed within a control panel, which is in turn enclosed within the control cabinet. Power is literally funnelled to and through the cabinet, and the controls within the panel dictate how much power gets distributed to the rest of the system and where it goes, while also monitoring the power system’s health. There are multiple control cabinets in a single warehouse – taken together, the individual control cabinets comprise the power distribution system for the warehouse. The warehouse’s power distribution system is only as strong as its control cabinets. ● Charging stations: A charging station supplies electrical power for plug-in electric vehicles such as electric forklifts and AMRs. Years ago, charging spots were all housed in one “room” on-site at the warehouse, charging locations are now found throughout the distribution and fulfilment centre, allowing equipment to more efficiently charge just about wherever and whenever needed. However, providing that ability to “charge on the go” means warehouse operators must either proactively design their power distribution infrastructure to accommodate many charging locations, or retroactively update the power system to allow for it. This can be a significant logistical challenge to solve.
Challenges faced when designing power distribution infrastructure Many people imagine power distribution like a river running continuously to its destination
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– power starts at one end and is delivered at the other. In reality, achieving proper power distribution in an automated warehouse is more like a complex network connected to the energy management. Communication and safety are just as important as speed and efficiency, and there are plenty of checks along the way.
Here are four key power distribution challenges that our warehouse customers frequently face: ● Safety concerns. If there’s a problem with power or electricity, warehouse operators must be able to quickly shut down machines to protect people and equipment. This requires an automatic power-off feature within power distribution infrastructure. ● Power spikes. A power spike can significantly damage sensitive equipment and components. Therefore, power distribution infrastructure must include adequate circuit protection to guard against excessive power output. ● Increased data. Warehouse operators rely on high-speed and real-time communication to maximise their operation, and reliable power distribution makes that possible. As data rates increase, power distribution must keep up. ● Faster charging speed. Modern warehouses run 24/7, so electric forklifts,
AGVs and AMRs need to charge quickly. That requires a power distribution system that can handle high loads, ranging from 40A to more than 400A in the future.
Warehouse operators – and the design engineers who build automated systems to support them – depend on hardy yet flexible contacts. These robust, reliable power connections are what enable the level of control and intelligence that distribution and fulfilment centres require to stand out in a competitive marketplace. Reliable power connectors simplify assembly efforts and help reduce safety hazards, and TE Connectivity’s products can help improve power distribution capabilities between the charger, battery, and drive system. Our connectors offer multiple contact points to support high-vibration tolerance, and our large product portfolios serve a wide variety of uses and compact designs. TE Connectivity is bringing the expertise and products needed to create a charging infrastructure that is faster, safer, smaller, and more flexible for automated warehouses. We’re dedicated to helping build the digital infrastructure needed for Industry 4.0. If you have questions about how to take your distribution and fulfilment centre to the next level, please contact one of our experts.
https://www.te.com/
www.cieonline.co.uk
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