Long item automatic storage system Unit Load AS/RS

for automotive applicationsboxpallet

Overview
Renowned for its high-density pallet storage, rapid operation, and adaptability, Daifuku’s Unit Load Automated Storage and Retrieval System (AS/RS) is a versatile automated pallet storage and retrieval solution customizable to specific installation environments and operational requirements. The system can be designed up to 40 meters in height and integrates stacker cranes, control systems, and peripheral equipment to suit load profiles and environmental conditions.

Features

• Fast and Dependable - Variety of AS/RS stacker crane types to fit load profile and operating environment; high-quality drives for fast, smooth, and reliable performance.
• Advanced Control System - Local intelligent network control from front-end controls to full-scale inventory management; real-time monitoring for troubleshooting and management of peripheral equipment.
• Improved Operational Efficiency - High-speed stacker cranes reduce cycle times and forklift traffic; energy-efficient practices including power regeneration and low electricity consumption.

Load Handling
From industrial pallets to odd-shaped loads, the stacker crane can handle an array of items.

• Closed pallets - pallets with closed bottom surfaces (examples: JIS T11 1100 x 1100, UK pallet 1000 x 1200).
• Euro pallets - standard skid pallets widely used in Europe and Asia (800 x 1200 and 1000 x 1200).
• Box pallets - four-legged box pallets commonly used for machine parts (handling depends on box foot shape).
• Roll-shaped loads - paper rolls, film sheets, textile rolls, carpets.
• Long objects - high-density storage for long pipes, bars, and plates up to 6.2 m long.
• In-progress car bodies - painted car body buffering in automotive plants.

Special Environments
Models and specifications are available to meet diverse installation environments and stored item characteristics.

• Fresh and frozen environments - cold-resistant stacker cranes for frozen foods (approx. -5°C to -30°C).
• Cleanroom environments - cleanroom-capable systems to meet ISO Class 6–7 requirements for food, pharmaceutical and precision equipment manufacturers.
• Oily and dusty environments (FMS) - specially designed, highly accurate stacker cranes for 24-hour automatic supply/collection of jigs to/from machining centers with features to ensure precise and stable operations.

Configuration
Multiple rack and crane configurations support different density and throughput needs.

• Single-deep AS/RS - standard configuration: one stacker crane with access to two rack rows (one on each side).
• Double-deep AS/RS - single stacker crane accesses four rack rows (two on each side) for higher density with lower throughput requirements.
• Dual crane AS/RS - two stacker cranes operate simultaneously in the same aisle to maximize throughput capacity and resiliency.
• Earthquake countermeasures - additional stoppers, special racking and other measures to minimize earthquake damage.

Add-ons
Peripheral equipment and add-ons to extend functionality and automation.

• Shuttle Cart - electrically powered cart transports pallets to/from the stacker crane load/unload point.
• End-of-aisle conveyors - automatically transport pallets to and from load/unload stations and transfer to/from STVs.
• Rack side conveyor - places input/output conveyor beside AS/RS for streamlined supply to presses and processing machines.
• Sorting Transfer Vehicle (STV) - rail-guided vehicle system to transport and sort pallets and connect AS/RS aisles to conveyors.
• Case picking robot - automates palletizing and depalletizing of case goods when combined with AS/RS.
• Rack-side pick-to-light - uses rack sides as picking windows with sliding shutters for operator safety.

Model Systems
Three model systems illustrate AS/RS movement and integration with peripheral equipment, showcasing options to match throughput and layout needs.

Characteristics / technical specifications

• Product name / series: Unit Load AS/RS
• Maximum structure height: up to 40 m (system customizable to site)
• Supported pallet types and sizes: JIS T11 (1,100 x 1,100), UK pallet (1,000 x 1,200), Euro pallets (800 x 1,200 and 1,000 x 1,200), box pallets (four-legged), and various odd-shaped loads.
• Long object handling: up to 6.2 m length for pipes, bars, plates.
• Cold storage capability: environmental spec down to approximately -30°C (typical cold-resistant range -5°C to -30°C).
• High-temperature spec: models available for 40°C to 55°C environments.
• Cleanroom capability: design options to meet ISO Class 6–7.
• Special environment options: oil-resistant / dusty environment specifications and FMS support for machining center integration.
• Configurations: single-deep, double-deep, dual crane (two cranes in one aisle) and seismic countermeasures available.
• Energy features: high-speed drives, energy-efficient operation, power regeneration functions.
• Peripheral equipment: shuttle carts, end-of-aisle conveyors, rack-side conveyors, STV rail-guided vehicles, case picking robots, rack-side pick-to-light systems.