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Cartons of different sizes stored four-deep

One of the decisive factors in the decision in favor of Hörmann Logistik was an innovative concept for the automated small parts warehouse, in which cardboard boxes and small load carriers (KLT) of various sizes can be stored. This automated small parts warehouse (AKL) is integrated into the silo construction of the pallet high-bay warehouse and is built at the same height of 25 meters. This unusual height for a mini-load warehouse could only be achieved by using a special design for the storage and retrieval machines, in which only one drive unit drives both the chassis and the mast head via a rack. With a special gripper technology, the different cartons can be stored up to four-deep. Several width classes allow volume-optimized allocation of the shelves.

To prevent fires, both the single-aisle pallet high-bay warehouse and the double-aisle carton high-bay warehouse are operated with an oxygen-reduced atmosphere. At goods receipt, pallets and cartons are identified with barcode labels in the warehouse management system, checked for weight and contour and placed on the conveyor system. Precise, camera-based contour detection is then used to assign the cartons to a width class.

Fine positioning through camera optics

The pallets are transported via the conveyor system to the airlock to the storage zone and, after passing through the airlock, are made available at the storage point of the pallet high-bay warehouse. The fully automatic storage and retrieval machine (SRM) picks up the pallet and stores it in the storage location specified by the Hörmann intra Logistics System, Hi LIS for short.

The SRM is equipped with a camera compartment fine positioning system for precise positioning. The camera optics detect the positioning hole attached to the storage location and align the compartment approach in the X and Y directions with millimetre precision to the center of the hole. The correct values are stored in the control system and used for the next compartment approach. This system also automatically adapts to changes in approach positions, for example due to load or wind effects.

Depending on the size of the cartons and the optimum compartment allocation, the Hi LIS warehouse management system decides whether or not to turn the cartons on the transport route towards the miniload. Continuous conveyors transport the cartons through an airlock to various sorting lanes, where cartons of the same size classes are sorted into pairs or quadruples and then stored together. The quadruple transport significantly reduces the number of stacker crane trips.

Cartons in the correct sequence at the pick & pack station

For retrieval, Hi LIS receives the orders from the host computer. By forwarding the retrieval orders at an early stage, Hi LIS can link orders of the same width class and thus also collect up to four cartons in the miniload via the stacker crane and make them available at the retrieval point. It is also possible to sort the cartons before feeding them to the Pick&Pack stations at the picking station if there are sequence requirements for the respective order. Each Pick&Pack station has its own carton buffer in which several cartons are temporarily stowed in order to continuously supply the Pick&Pack stations with goods. The operator of the Pick&Pack station receives the order at his terminal, picks it and prepares the goods for dispatch.

Pallet lowers to the correct height

The pallets are also requested via Hi LIS in the high-bay pallet warehouse, retrieved by the stacker crane and transported to the pick & pack stations via the airlock. To enable the operator to work ergonomically, a scissor lift table lowers the pallets to working level. The operator removes the corresponding items displayed on the terminal. The opened pallet is transported back to the pallet warehouse through the airlock and stored. The operator prepares the removed items for dispatch.

The three storage and retrieval machines work with the Hi LIS eco power management system, which saves up to 25 percent of energy consumption through intelligent energy balancing. The Hi LIS system visualization makes it possible to track and control all system movements in real time.

Production operations started successfully in November 2015.

Contact:Kern & Sohn GmbH 72336 Balingen-Frommern Tel.: 0 74 33 / 99 33-0 E-Mail: [email protected] www.kern-sohn.com

Hörmann Logistik GmbH 80992 Munich Tel.: 0 89 / 14 98 98-0 E-Mail:[email protected] www.hoermann-logistik.de