Definition
Due to their efficient use of space for storing goods, these warehouses are often metaphorically referred to as "three-dimensional warehouses."
Automated Storage and Retrieval Systems (AS/RS) represent a revolutionary achievement in logistics technology. Typically consisting of high-rise racks, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS), they can automatically handle the storage and retrieval of unit loads under computer system control.
History of Development
The emergence and development of automated storage and retrieval systems (AS/RS) are the result of production and technological advancements. In the early 1950s, the U.S. saw the advent of AS/RS utilizing bridge cranes; by the late 1950s and early 1960s, driver-operated aisle cranes in AS/RS were introduced; in 1963, the U.S. was the first to implement computer control technology in high-bay warehouses, establishing a computer-controlled AS/RS. Subsequently, AS/RS automated systems experienced rapid growth in both the U.S. and Europe, giving rise to a specialized field. In the mid-1960s, Japan began to develop AS/RS, with an increasingly rapid pace, and has become one of the countries with the most automated AS/RS in the world today. China's research and development of AS/RS and material handling equipment did not start late; in 1963, a bridge crane (from the Beijing Research Institute of Lifting and Transportation Machinery of the Ministry of Mechanical Industry) was developed. In 1973, China began to develop an AS/RS controlled by computers (15 meters tall, with the Lifting Machinery Research Institute of the Ministry of Mechanical Industry responsible), which was put into operation in 1980. As of now (2009), China has more than 1,200 automated AS/RS. Due to their high space utilization, strong inbound and outbound capabilities, computerized control, and their benefits in implementing modern management practices, AS/RS have become an indispensable storage technology for corporate logistics and production management, and are increasingly valued by businesses.
Application
The application range of automated vertical warehouses is extensive, spanning nearly all industries. In our country, the main industries utilizing automated elevated warehouses include machinery, metallurgy, chemicals, aerospace, electronics, books, food processing, tobacco, printing, distribution centers, airports, and ports.
Basic Composition
The automated vertical warehouse is basically composed of the following components:
4.1 High Bay Racks: Steel structural systems used for storing goods. Currently, there are mainly two basic types: welded racks and assembled racks.
4.2 Pallet (Container): A device used for carrying goods, also known as a work station tool.
4.3 Conveyer Stacker: Equipment for automatic loading and unloading of goods. Divided into two basic types according to structure: single-column and double-column; and into three basic types according to service method: straight, curved, and transfer vehicle.
4.4 Conveying System: The main peripheral equipment of the automated storage and retrieval system, responsible for delivering goods to or removing them from the stacker. There are many types of conveyors, including roller conveyors, chain conveyors, lifting platforms, distribution vehicles, lifting machines, belt conveyors, etc.
4.5 AGV System: Automated Guided Vehicle. Divided into inductive guided vehicles and laser guided vehicles based on their guidance methods.
4.6 Automatic Control System: The automatic control system that drives the various equipment of the automated storage and retrieval system. Currently, the field bus method is mainly used as the control mode.
4.7 Inventory Information Management System (WMS): Also known as the Central Computer Management System. It is the core of the fully automated three-dimensional storage system. Currently, typical automated three-dimensional storage systems all use large database systems (such as ORACLE, SYBA, etc.).Establish typical client/server architectures (such as se), which can be networked or integrated with other systems (like ERP systems).
Superiority
The advantages of an automated vertical warehouse are multifaceted, and for businesses, they can be reflected in the following aspects:
Space utilization
5.1 Enhance Space Utilization: The early concept of the three-dimensional warehouse was primarily focused on enhancing space utilization, fully conserving the limited and valuable land. In some developed countries in the West, the concept of space utilization has taken on a more profound meaning, where conserving land has been linked to saving energy, environmental protection, and other aspects. Some even consider the space utilization as a crucial indicator for evaluating the rationality and advancement of the system. The space utilization of a three-dimensional warehouse is closely related to its planning. Generally speaking, automated high-rise warehouses have a space utilization rate 2-5 times higher than that of conventional flat warehouses, which is quite remarkable.
Logistics System
5.2 Facilitates the development of advanced logistics systems and improves the level of enterprise production management. Traditional warehouses are merely places for storing goods, with the primary function being to preserve them, which is a "static storage" method. Automated vertical warehouses use advanced automated material handling equipment, enabling goods to be automatically stored and retrieved within the warehouse as needed. They also facilitate organic connections with production processes outside the warehouse, turning the warehouse into a key component of the enterprise's production logistics through computerized management systems and automated material handling equipment. The storage of externally purchased components and self-manufactured production parts in an automated warehouse is a stage in the entire production process. Short-term storage is to automatically output to the next production stage, thus forming an automated logistics system. This is a "dynamic storage" method and a clear technical trend in the development of automated warehouses today. The aforementioned logistics system is also a subsystem of the entire enterprise production management system (from ordering, necessary design and planning, scheduling and production arrangement, manufacturing, assembly, testing, dispatching, etc.). Establishing real-time connections between the logistics system and the enterprise's larger system is another clear technical trend in the development of automated high-bay warehouses. Modern enterprises have higher requirements for management, and the mindset of "management creates benefits" has become a consensus among most modern enterprise managers.
Production management is a crucial component of enterprise management, encompassing product planning, production organization, logistics planning, procurement of external equipment, product quality, cost estimation, and more. As a central part of the production process, the automated high-bay storage system is almost involved in the entire production management process.
Access rhythm
5.3 Accelerate the pace of goods storage and retrieval, reduce labor intensity, and improve production efficiency. Establish a logistics system centered around an automated vertical warehouse, which also boasts the advantage of rapid intake and output capabilities in the automated high-rack storage, enabling quick and proper storage of goods (inventory) and the timely and automatic delivery of required components and raw materials to the production line. This feature is unattainable by ordinary flat warehouses. Additionally, the implementation of an automated vertical warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Replacing manual handling of goods with automated aisle stackers, which is both quick and labor-saving. Since workers do not need to enter the warehouse, the working environment is greatly improved. 2) Utilizing a computer management system for goods management, significantly enhancing management capabilities, making warehouse management more scientific, with improved accuracy and reliability. Tasks such as inventory management, stocktaking, and reporting become simpler and faster, greatly reducing labor intensity. 3) Assisted by front-of-warehouse conveying equipment, the intake and output process becomes easier and more convenient. 4) The automated vertical warehouse system requires minimal staff for operation and system maintenance, saving both labor and resources, conserving funds, and improving the working environment—multiplying benefits.
Excess inventory
5.4 Reducing Inventory Capital Pressure After investigating some large enterprises, it has been found that due to historical reasons, management methods are outdated, material management is scattered, making it difficult to achieve a tight connection between production management and production processes. To meet expected production capacity and demands, sufficient raw materials and components must be prepared, leading to inventory accumulation as a significant issue. How to reduce inventory capital pressure and fully meet production needs has become a major challenge for large enterprises. The high-rise storage system is one effective means to address this problem. 1) A factory logistics system centered around automated storage has resolved circulation and supply-demand conflicts in various production stages, allowing the supply of raw materials and the production of components to reach an optimal balance. 2) The establishment of a computer network system has made the procurement of raw materials and components more timely and in line with actual demands. 3) The establishment of a computer management system has strengthened macro-control functions, enabling production quantities at each stage to better meet actual needs. 4) The establishment of finished product and semi-finished product warehouses helps address temporary discrepancies in market supply and demand, fully utilizing the company's production potential. 5.5 Symbol of Modernized Enterprises Modernized enterprises adopt intensive large-scale production models, requiring close connections between all stages of production to form an organic whole. Production management must be scientific and practical, with decision-making being scientific. Establishing an automated high-rise storage system is one powerful measure to achieve this. As previously mentioned, the automated logistics system has unparalleled advantages in maximizing space utilization, meeting production requirements, reducing labor intensity, increasing production efficiency, enhancing production and material management, and reducing inventory capital pressure, all of which are what modernized enterprises require and pursue. Due to the adoption of computer management and network technology, it is now possible for corporate leaders to quickly grasp various material information and for engineers, production managers, and technical staff to promptly understand inventory information to arrange production processes and improve efficiency. The Internet and the company's internal network provide a vast space and robust technical support for online connections with the outside world, breaking information bottlenecks, broadening horizons, and promoting external and internal integration. In reviewing large enterprises at home and abroad, since the 1960s, the gradual adoption of automated logistics systems has become an indispensable part of corporate production management. According to statistics, Japan has already established over 8,000 automated high-rise warehouses (logistics systems). Establishing an automated high-rise storage system has become one of the important symbols of modernized enterprises.
