Multi-level axle storage and conveyor line

Multi-level axle storage and conveyor line

Multi-Level Axle Storage & Conveyor Line – Technical Specification (Generic Version)

  1. Target Performance
  • Capacity: ≥ 3 000 axles, 1.8–2.4 m long, 80–120 kg each
  • Levels: 3–5 tiers within 6 m total height, no civil work
  • Throughput: 60 axles/h inbound, 80 axles/h outbound, dual-station capable
  • Zero damage: all contact faces copper- or PU-lined
  • IT: barcode/RFID tracked, real-time interface to MES/ERP
  1. System Modules
    a. Rack
  • Beam + cantilever, one axle per cell, 900 mm tier pitch, 1.5 t load per cell
  • Cell clear: L 2 600 × W 650 × H 900 mm (fits φ230 brake disc)

b. Stacker crane (in-rack handling)

  • Single or double mast, servo travel & lift, fork with copper-lined cradle
  • Laser positioning ±2 mm, barcode verification; safety edges + area scanner, SIL2/PLd

c. Gantry robot (dock-to-rack interface)

  • Modular bridge spanning rack and conveyor; nitrogen-balanced servo lift, ±0.5 mm repeatability
  • 360° servo rotation, copper-lined clamp, adjustable force 0.3–0.6 MPa, vision-ready

d. In-/out-bound roller conveyor

  • φ89 galvanized rollers, chain drive, sectional VFD, 150 kg per axle
  • Pneumatic centering ≤1 mm deviation; optional 90°/180° rotation table

e. Control & software

  • PLC: 1516-3 PN, Profinet; WCS links to upstream line via OPC-UA
  • Safety network SIL2/PLd, stop time ≤500 ms
  1. Typical Footprint
    Rack: 28 m × 6 m × 5.5 m, 5 tiers, 1 200 cells
    Aisle: 1 300 mm; gantry leg centres 8 m, head-room 6 m
    Floor load: rack zone 2 t/m², rail zone 3 t/m², 200 mm reinforced concrete
  2. Workflow
    Inbound: roller scan → centre/rotate → gantry pickup → inbound buffer → crane stores → WCS updates stock
    Outbound: MES order → WCS assigns → crane retrieves → outbound buffer → gantry to roller → to line
  3. Key Interfaces
  • Existing PLC (S7-300) linked via DP/DP-Coupler; cycle data exchanged in real time
  • Peak 90 axles/h met by dual cranes or dual gantries
  • Gripper & fork dimensions match current fixtures; no tooling change needed
  1. Optional Upgrades
  • On-line chamfering/stamping station integrated in conveyor
  • 2D camera inside gripper for flange engraving verification, preventing mix-ups
  • Lights-out operation: full-area laser scanners + infrared monitoring for unmanned shift

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