An automated stereoscopic warehouse integrates advanced structures, control systems, and software to optimize storage and logistics. Its high-rise racking maximizes space utilization, while stacker cranes and conveyors enable efficient goods handling. The control system, featuring PLCs and sensors, ensures precise operations. The software, including WMS and identification systems, enhances inventory management and tracking. This integration of hardware and software boosts warehouse efficiency, accuracy, and overall performance, making it a vital solution for modern logistics and storage needs.
I. Structure of the Automated Stereoscopic Warehouse
- Racking System
- The core component of an automated stereoscopic warehouse, typically consisting of high-rise racking used for storing goods. The racking can be made of steel or reinforced concrete and comes in various types such as unit-load, drive-through, horizontal rotation, and vertical rotation styles.
- Unit-load racking is similar to pallet racking, with aisles occupying about one-third of the space. Drive-through racking eliminates aisles, allowing goods to be stored along a continuous path, divided into gravity-fed racking warehouses and shuttle-based racking warehouses.
- Horizontal rotation racking can move along a circular path in the horizontal plane and is suitable for the picking operations of small items.
- Goods Storage and Conveyance System
- Mainly includes aisle stacker cranes, in-and-out conveyors, and loading/unloading machinery.
- Aisle stacker cranes are used for storing and retrieving goods within the racking aisles. Their movement is driven by stepper motors and features three degrees of freedom: horizontal, vertical, and forward/backward.
- Conveyors are used for the in-and-out transportation of goods, typically employing belt conveyors or roller conveyors.
- In-and-Out Workstations
- Used for the in-and-out operations of goods, serving as the interface for goods to enter and leave the warehouse.
- Auxiliary Facilities
- Including the building structure, doors and windows, and flooring. The building structure usually adopts a portal frame structure to maximize the internal space. The flooring must be flat, wear-resistant, dust-free, slip-resistant, and easy to clean.
II. Control System of the Automated Stereoscopic Warehouse
- Control Methods
- There are various control methods for automated stereoscopic warehouses, including single PLC control, networked control, centralized control, split control, and distributed control.
- More advanced automated stereoscopic warehouses use a combination of centralized control, split control, and distributed control, consisting of management computers, central control computers, and programmable logic controllers (PLCs) that directly control stacker cranes, in-and-out conveyors, and other equipment.
- Hardware Components
- PLC: The core component of the control system, used to achieve automated control of stacker cranes, conveyors, and other equipment. The selection of PLCs is determined based on the system’s functional requirements and the number of I/O points.
- Sensors: Used to detect the position of goods and the status of equipment, such as photoelectric sensors and proximity switches.
- Motors and Drives: Typically using stepper motors as the driving elements, stepper motor drivers are used to control the movement of the motors.
- Communication Equipment: Used to enable communication between PLCs, upper-level computers, and various equipment.
- Software Design
- PLC Program Design: The ladder diagram program is designed according to the working requirements to achieve automated control of the equipment. The program includes control logic for both manual and automatic operation modes.
- System Debugging: The program is input into the PLC for software testing to identify errors and ensure the perfection of the system program.
III. Software of the Automated Stereoscopic Warehouse
- Warehouse Management System (WMS)
- Serving as the core of the automated stereoscopic warehouse system, it is responsible for managing product information, monitoring inventory levels, optimizing storage space distribution, processing orders, and controlling the in-and-out processes of goods.
- Its advanced algorithms can predict material requirements, automatically allocate resources, optimize picking routes, reduce operation time, and improve out-of-warehouse efficiency. Additionally, it can generate various reports to support decision-making.
- Goods Identification System
- Using barcode or Radio Frequency Identification (RFID) technology to ensure accurate input and tracking of goods information.
- Automated Control System
- Responsible for commanding the automated equipment to complete assigned tasks, achieving automatic storage, in-and-out functions of goods.
- Data Communication System
- Ensuring real-time and efficient transmission of information between different parts to ensure the coordinated operation of the entire system.
- Monitoring System
- Real-time monitoring of warehouse status and goods information, providing accurate inventory data and operation reports.
Automated stereoscopic warehouses, through their complex structures, advanced control systems, and efficient software, achieve automated and intelligent warehouse operations, improving warehouse efficiency and management levels.