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

2. 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
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Overview of AS/RS
AS/RS refers to a variety of computer-controlled methods for automatically depositing and retrieving loads from defined storage locations.
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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

5. 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
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Concept of AS/RS
The operation are totally automated
Computer controlled
Fully integrated with
factory and warehouse
operations
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7. 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
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8. 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
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9. 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
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10. 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
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11. 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.
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12. Basic Structure of AS/RS
5. External handling system - brings loads to the AS/RS and takes loads away. ex) RTV(Robotic Transfer Vehicle)
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13. Basic Structure of AS/RS
AS/RS Structure
- automatically operated
- can reduce wasted storage place
- protect product
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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.
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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.
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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
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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
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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)
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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
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Application Example
FedEx
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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
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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.
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23. 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

24. Horizontal Carousel Storage System
Manually operated horizontal carousel storage system

25. 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

26. 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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THANK YOU
THANK YOU
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