AS/RS (Automated Storage/Retrieval System) Chaitanya. M 1MS10MCM04 Department of Mech. Engineering

Department of Mech. Engineering Contents Overview of AS/RS Problems of conventional storage system About AS/RS -concept -structure -control -benefit -design issue Carousel storage systems Application example Conclusion Department of Mech. Engineering

Department of Mech. Engineering Overview of AS/RS AS/RS refers to a variety of computer-controlled methods for automatically depositing and retrieving loads from defined storage locations. Department of Mech. Engineering

Department of Mech. Engineering Overview of AS/RS AS/RS are used widely in both Manufacturing and Distribution operations to hold and buffer the flow of material moving through the process to the ultimate end-user. Department of Mech. Engineering

Problems of Conventional Storage System Much time spend for searching lost or damaged products and inaccurate records Orders spending too much time in the factory, causing customer deliveries to be late. Waste much space excess inventory Workers are exposed dangers => Need AS/RS Department of Mech. Engineering

Department of Mech. Engineering Concept of AS/RS The operation are totally automated Computer controlled Fully integrated with factory and warehouse operations Department of Mech. Engineering

Basic Structure of AS/RS Storage structure S/R(storage/retrieval) machine Storage modules e.g.) pallets for unit loads One or more pickup-and deposit station External handling system Department of Mech. Engineering

Basic Structure of AS/RS 1. Storage structure - which is the rack framework - made of fabricated steel - supports the loads contained in the AS/RS Department of Mech. Engineering

Basic Structure of AS/RS 2. S/R machine - is used to accomplish storage transaction, delivering loads from the input station into storage, and retrieving loads from storage and delivering Department of Mech. Engineering

Basic Structure of AS/RS 3. Storage modules - are the unit load containers of the stored material. - include pallets, steel wire baskets and containers, plastic tote pans Department of Mech. Engineering

Basic Structure of AS/RS 4. Pick-and-deposit station - is where loads are transferred into and out of the AS/RS. - generally located at the end of the aisles for access the external handling system that brings loads to the AS/RS and takes loads away. Department of Mech. Engineering

Basic Structure of AS/RS 5. External handling system - brings loads to the AS/RS and takes loads away. ex) RTV(Robotic Transfer Vehicle) Department of Mech. Engineering

Basic Structure of AS/RS AS/RS Structure - automatically operated - can reduce wasted storage place - protect product Department of Mech. Engineering

Department of Mech. Engineering Control Using computer Principle problem - positioning the S/R machine within an acceptable tolerance at a storage compartment in the rack structure to deposit or retrieve a load. Department of Mech. Engineering

Department of Mech. Engineering Control Positioning method 1) counting procedure     - the number of bays and levels are counted in the direction of travel(horizontally and vertically) to determine position 2) numerical identification procedure     - each compartment is provided with a reflective target with binary-coded location identifications on its face. Department of Mech. Engineering

Department of Mech. Engineering Control Optical scanners are used to read the target and position the shuttle for depositing or retrieving a load Ex- Scanners read RFID-tags on pallets. (RFID-tags have information like compartment binary-code(position), sections, and etc...) Each time a storage transaction is completed, the transaction must be recorded into the computer Department of Mech. Engineering

Department of Mech. Engineering Control Computer controls - storage transaction can be entered in real-time - inventory records can be accurately maintained - system performance can be monitored - communications can be facilitated with other factory computer systems Department of Mech. Engineering

Department of Mech. Engineering Benefits Improve operator efficiency and storage capacity Increasing accuracy Maximize available storage space Reducing labor costs Reducing product damage and waste costs Increasing customer service (e.g. : fast delivery) Real time inventory control Removing personnel from difficult working condition (such as cold food storage environments) Department of Mech. Engineering

Department of Mech. Engineering Design issue Structure part - Height and Length of storage structure - Storage module size - Aisle width - Load capacity - Horizontal and vertical speed & acceleration Controller part - Positioning method - Record method Department of Mech. Engineering

Department of Mech. Engineering Application Example FedEx Department of Mech. Engineering

Department of Mech. Engineering Application Example FedEx - They bring a lot of parcels and packages, and sort them with some standards (such as delivery zone) And then they load some parcels and packages into delivery trucks and deliver articles at house Department of Mech. Engineering

Department of Mech. Engineering Conclusion AS/RS is in use and can be used many kinds of manufacturing line & distribution centers. Using AS/RS with proper design will produce above mentioned many kinds of benefits. Department of Mech. Engineering

Carousel Storage Systems Horizontal Operation is similar to overhead conveyor system used in dry cleaning establishments Items are stored in bins suspended from the conveyor Lengths range between 3 m and 30 m Horizontal is most common type Vertical Operates around a vertical conveyor loop Less floor space required, but overhead room must be provided

Horizontal Carousel Storage System Manually operated horizontal carousel storage system

Carousel Applications Storage and retrieval operations Order picking Kitting of parts for assembly Transport and accumulation Progressive assembly with assembly stations located around carousel Work-in-process WIP applications in electronics industry are common Unique applications Example: time testing of electrical products

Engineering Analysis of Automated Storage Systems Automated Storage/Retrieval Systems Sizing the AS/RS AS/RS throughput analysis Carousel storage systems Storage capacity Throughput analysis

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