Dynamic duo: two storage and retrieval machines in one aisle
High performance within a confined space
When modernising its production warehouse, GERMANIA, the Westphalian manufacturer of household and office furniture, placed particular emphasis on performance and speed. MLOG Logistics were commissioned to carry out the refurbishment, exchanging the two storage and retrieval machines (SRM’s) that were installed in one aisle for two new ones from its own production portfolio. The result is impressive in terms of the high throughput and short cycle times provided by the high-performance combination. The existing racking construction was retained, even though it had settled over the years and thus made the positioning of the SRM’s more difficult.
GERMANIA Werk Krome GmbH is a major manufacturer of high quality, attractive and contemporary flat-pack furniture. For more than 50 years, its head office has been located in Schlangen, Westphalia, one of the most significant regions for the German furniture industry. A great many businesses have become established there in recent decades and many of them operate a high-bay warehouse supplied by MLOG Logistics GmbH, a company which has earned a good reputation in the sector through its innovative developments specifically for the furniture industry. For kitchen production, for example, the Neuenstadt-based company has special load carrying equipment in its range, which can even pick up sensitive surfaces gently and safely by using suction grippers, enabling heavy worktops to be stored up to three deep.
The factory in Schlangen extends over an area of 50,000 m2 with highly automated production of household and office furniture. Because of a continuous increase in demand, the entire plant has been modernised to a considerable extent, including the replacement of two old SRM’s by MLOG. Due to site constraints, the new, 32 metre high devices could only be lowered into position through the roof. After removing a girder in the roofing structure, the opening through which they were brought into position in the common aisle, measured just 7 x 2 metres.
Equipping an aisle with two machines is a particularly complex undertaking from several perspectives. In this case the single column MSINGLE storage and retrieval machines, produced in-house by MLOG in Germany, form the basis for this. Using digital absolute encoders and laser measurement equipment they detect their respective positions with high precision and are also equipped with onboard camera systems. Each system consists of two camera modules with a lens and megapixel colour sensors. The recorded images are immediately available on the network via Ethernet connection.
The two MSINGLE machines are perfectly coordinated and synchronised when working between the racks and order picking stations. Laser systems ensure that the devices always work with the required clearances. The maximum travelling speed of the machines is 160 m/min and the maximum lifting speed is 80 m/min. The speeds are infinitely variable and are continuously controlled and adjusted by the use of inverter modules; this is also an economical solution from an energy perspective, since the current consumption of the modern drives is well below that of conventional motors.
The special challenges posed by the installation included the integration of the control systems with the higher-level warehouse management system. The SRM’s which were replaced were originally operated with two further devices via a common control system. Therefore, these first had to be removed from the existing control system whilst maintaining all existing interfaces.
Precise positioning in front of the racking bays is an important key to efficiency and availability. Ultimately, every millimetre counts in the storage and retrieval of high-quality goods to avoid storage collisions. In Schlangen, however, the initial input of the shelving bay positions into the control system proved to be complex. As is often the case in existing buildings, the rack structure had settled over the course of the years. However, due to the highly precise positioning of the drive technology used, it was possible to overcome these shelf positioning difficulties.
Short project period in spite of obstacles
Thanks to the most careful planning and preparation, and also to the excellent preliminary work by the client, the modernisation was completed rapidly and smoothly. The provision of professional scaffolding by the customer during the SRM installation phase greatly facilitated the replacement operation. From the dismantling and removal of the old SRM’s through to the adjustment and installation of the new SRM’s and then through to commissioning took only 20 days.
Here you can get more information about GERMANIA.
Your contact for this project:
Jens Tangel
phone +49 (0) 7131.136-245
fax +49 (0) 7131.136-394
jtangel[at]mlog-logistics.com
External view of the production warehouse in Schlangen, Westphalia.
The two MSINGLE SRM’s were installed in one aisle to replace two older models.
The 32 metre high MSINGLE machines are precisely coordinated by laser systems and synchronised when working within the racks and order picking stations in the production warehouse.
Every millimetre counts in front of the shelving bay – thanks to the high-precision positioning of the drive technology installed, precise positioning of the shelves was unnecessary.
