Definition
Due to their ability to maximize 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 comprising high-level racking, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS), they can perform automated storage and retrieval operations for individual items under the control of a computerized system.
Development History
The emergence and development of automated storage and retrieval systems (AS/RS) are the results of production and technological advancements. In the early 1950s, the U.S. saw the introduction of AS/RS using bridge cranes; by the late 1950s and early 1960s, driver-operated aisle cranes were implemented in AS/RS; in 1963, the U.S. was the first to adopt computer control technology in high-bay warehouses, establishing a computer-controlled AS/RS. Subsequently, AS/RSs automated rapidly in the U.S. and Europe, forming a specialized discipline. In the mid-1960s, Japan began to develop AS/RSs, with increasing speed, becoming one of the countries with the most AS/RSs in the world today. China's research and development of AS/RS and material handling equipment did not lag behind; in 1963, a bridge crane was developed (by the Beijing Lifting and Transportation Machinery Research Institute of the Ministry of Machinery); in 1973, China began developing an AS/RS controlled by computers (15 meters tall, responsible by the Lifting Institute of the Ministry of Machinery), which was put into operation in 1980. As of now (2009), China has over 1,200 automated AS/RSs. AS/RSs, due to their high space utilization, strong incoming and outgoing capabilities, and computerized control management, are essential for modern management in enterprises, and are increasingly valued by businesses.
Application
Automated vertical storage systems have a wide range of applications, spanning nearly all industries. In our country, the main industries utilizing automated high-rise warehouses include machinery, metallurgy, chemicals, aerospace, electronics, books, food processing, tobacco, printing, distribution centers, airports, and ports.
Basic Components
The automated vertical storage system is essentially composed of the following parts:
4.1 High-Rack Storage: A steel structure used for storing goods. Currently, there are mainly two basic types: welded shelving and assembled shelving.
4.2 Pallet (Container): A device used for carrying goods, also known as a work station device.
4.3 Conveyer Stacker: Equipment for automatic loading and unloading of goods. Divided into two basic types by structure: single-column and double-column; and into three basic types by service method: straight, curved, and transfer vehicle.
4.4 Conveying System: The main peripheral equipment of the立体库, responsible for transporting goods to or from the stacker. There are many types of conveyors, commonly including roller conveyors, chain conveyors, lifting tables, distribution carts, hoists, belt conveyors, etc.
4.5 AGV System: Automatic 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 for driving various equipment of the automated storage and retrieval system. Currently, fieldbus-based control mode is predominantly used.
4.7 Warehouse Management System (WMS): Also known as Central Computer Management System. It is the core of a fully automated vertical storage system. Currently, typical automated vertical storage systems all use large database systems (such as ORACLE, SYbase).Build typical client/server architectures (e.g., SE) that can be networked or integrated with other systems (such as 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 initial concept of early three-dimensional warehouses was primarily focused on enhancing space utilization, fully conserving the limited and valuable land. In some developed countries in the West, the idea of improving space utilization has taken on a broader and more profound meaning, with land conservation being linked to energy conservation, environmental protection, and other aspects. Some even treat the space utilization rate as a key indicator for evaluating the rationality and advancement of the system. The space utilization rate 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 that of conventional flat warehouses, which is quite remarkable.
Logistics System
5.2 Facilitates the formation of advanced logistics systems and improves the level of enterprise production management. Traditional warehouses are merely places for storing goods, with the function of preservation being their primary role, a form of "static storage." Automated vertical warehouses utilize advanced automated material handling equipment, enabling not only the automatic storage and retrieval of goods within the warehouse as needed but also organic connection with production processes outside the warehouse. Through a computerized management system and automated material handling equipment, the warehouse becomes a crucial component of the enterprise's production logistics. The entry of externally purchased parts and self-manufactured production items into the automated warehouse is a stage in the entire production process, with short-term storage intended to automatically output to the next production stage, thereby forming an automated logistics system. This is a "dynamic storage" and represents a clear technical trend in the development of modern automated warehouses. The aforementioned logistics system is also a subsystem of the entire enterprise production management system (ranging from ordering, necessary design and planning, scheduling and production arrangement, manufacturing, assembly, testing, dispatch, etc.). Establishing real-time connections between the logistics system and the enterprise's larger system is another clear technical trend in the development of modern automated high-bay warehouses. Modern enterprises have higher demands on management, and the mindset of "management brings benefits" has become a consensus among most modern enterprise managers.
Production management is a crucial component of corporate management, encompassing product planning, production organization, logistics planning, procurement of external equipment, product quality, cost estimation, and more. The automated overhead storage system serves as a central link in the production process, participating almost throughout the entire production management process.
Deposit and withdrawal 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 the high-speed incoming and outgoing capabilities of the automated elevated storage. It can quickly and properly store goods in the elevated warehouse (incoming), as well as swiftly and promptly deliver the required parts and raw materials to the production line automatically. This feature is unattainable by conventional flat warehouses. Moreover, the implementation of an automated vertical warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Replacing manual goods storage and retrieval with automatic 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 computerized management system to manage goods significantly enhances the management capabilities of the warehouse, making warehouse management more scientific, with improved accuracy and reliability. Tasks like incoming and outgoing management, inventory, and reporting become simpler and quicker, greatly reducing the labor intensity for workers. 3) The vertical warehouse system is supplemented by front-of-warehouse auxiliary conveying equipment, making incoming and outgoing operations simpler and more convenient. 4) The automated vertical warehouse system requires very few operators and system maintenance personnel, saving both human and material resources, conserving funds, and improving the working environment, achieving multiple benefits with one move.
Excess Inventory
5.4 Reducing Inventory Capital Pressure Through investigations of some large enterprises, it has been found that due to historical reasons, management methods are outdated, material management is scattered, making it difficult to establish a tight connection between production management and production processes. To achieve expected production capacity and meet production requirements, an adequate supply of raw materials and components is necessary. This leads to significant inventory accumulation, which has become a major issue for large enterprises. How to reduce inventory capital pressure and fully meet production needs is a significant challenge that large enterprises must face. The high-rise storage system is one effective means to address this issue. 1) A factory logistics system centered around automated storage solves the circulation problems and supply-demand contradictions in various production stages. It ensures that the supply of raw materials and the production of components align with the required quantities. 2) The establishment of a computer network system makes the procurement of raw materials and purchased components more timely and meets actual demand. 3) The establishment of a computer management system strengthens macro-control functions, making production quantities in various stages more responsive to actual demand. 4) The establishment of finished product and semi-finished product warehouses addresses temporary inconsistencies in market supply and demand, fully leveraging the company's production potential. 5.5 Symbol of a Modern Enterprise Modern enterprises adopt intensive large-scale production models, requiring close connections between all stages of the production process 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, an automated logistics system offers unparalleled advantages in maximizing space utilization, meeting production requirements, reducing labor intensity, improving production efficiency, strengthening production and material management, and reducing inventory capital pressure. This aligns with the requirements and pursuits of a modern enterprise. 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 enterprise Intranet provide a vast space and robust technical support for online connections, breaking information bottlenecks, broadening horizons, and promoting external and internal integration. Overall, since the 1960s, large enterprises around the world have gradually adopted automated logistics systems, which have 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 a modern enterprise.
