Definition
Due to their ability to fully utilize space for storing goods, these warehouses are often metaphorically referred to as "three-dimensional warehouses."
The Automated Storage and Retrieval System (AS/RS) is a revolutionary achievement in logistics technology, typically comprising high-rise racks, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS). It enables the automated storage and retrieval of unit loads under the control of a computer 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 used 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. Since then, AS/RS has rapidly developed in the U.S. and Europe, evolving into a specialized discipline. In the mid-1960s, Japan began to develop AS/RS, and its pace of growth has accelerated, making it one of the countries in the world with the most automated AS/RS. China's research and development of AS/RS and material handling equipment did not start late; in 1963, a bridge crane was developed (by the Beijing Research Institute of Lifting and Transportation Machinery of the Ministry of Machinery); in 1973, China began to develop an automated 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/RS. Due to their high space utilization, strong inbound and outbound capabilities, computerized control and management, and their contribution to modern management, AS/RS have become an indispensable storage technology for corporate logistics and production management, and are increasingly valued by enterprises.
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 Composition
The automated vertical storage system is essentially composed of the following parts:
4.1 High Rack: A steel structure used for storing goods. Currently, there are mainly two basic types: welded racks and assembled racks.
4.2 Pallet (Container): A device used to carry goods, also known as a work station tool.
4.3巷道堆垛机: Equipment for automatic storage and retrieval 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 automated storage and retrieval system, responsible for transporting goods to or from the stacker. There are many types of conveyors, commonly including roller conveyors, chain conveyors, lift platforms, distribution vehicles, lift 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 for driving various equipment of the automated storage and retrieval system. Currently, fieldbus-based control mode is predominantly used.
4.7 Inventory Information Management System (WMS): Also known as the Central Computer Management System. It is the core of a fully automated three-dimensional storage system. Currently, typical automated three-dimensional storage systems all use large database systems (such as ORACLE, SYbase).Establish typical client/server architectures (such as se), which can be interconnected 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 realized in the following aspects:
Space Utilization
5.1 Enhance Space Utilization: The early concept of automated storage and retrieval systems (AS/RS) was fundamentally centered around enhancing space utilization and fully conserving the limited yet valuable land. In some developed countries in the West, the idea of space utilization has taken on a broader and deeper meaning, linking land conservation with energy conservation, environmental protection, and more. Some even consider space utilization as a key indicator for evaluating the rationality and advancement of a system. The space utilization of an AS/RS is closely tied to its planning. Generally, the space utilization rate of an automated AS/RS is 2 to 5 times that of a conventional flat storage facility, which is quite significant.
Logistics System
5.2 Facilitates the development of advanced logistics systems, enhancing the management level of corporate production. Traditional warehouses are merely storage facilities for goods; preservation is their function, representing a "static storage" method. Automated vertical warehouses utilize advanced automated material handling equipment, enabling not only automatic storage and retrieval of goods within the warehouse but also organic integration with production stages outside the warehouse. Through computer management systems and automated material handling, the warehouse becomes a critical link in the company's production logistics. The process of purchasing external components and producing in-house parts for storage in the automated warehouse is an integral part of the entire production process. Short-term storage is to automatically output to the next production stage, thereby forming an automated logistics system. This is a "dynamic storage" method and a clear technical trend in the development of modern automated warehouses. The aforementioned logistics system is also a subsystem of the overall corporate production management system (ranging from ordering, necessary design and planning, scheduling and production arrangement, manufacturing, assembly, testing, and dispatching, etc.). Establishing real-time connections between the logistics system and the overall corporate system is another clear technical trend in the development of automated high-bay warehouses. Modern enterprises have higher management requirements, and the "management generates benefits" mindset has become a consensus among most modern corporate managers.
Production management is a crucial component of corporate management, encompassing product planning, production organization, logistics planning, outsourced equipment, product quality, cost estimation, and more. As a central part of the production process, the automated high-bay storage system is involved in nearly the entire production management process.
Withdrawal and deposit rhythm
5.3 Accelerate the pace of goods storage and retrieval, reduce labor intensity, and enhance production efficiency. Establish a logistics system centered around an automated three-dimensional warehouse, which also boasts the advantage of rapid inbound and outbound capabilities of the automated high-bay storage, allowing for quick and proper storage of goods (inbound) and the timely and automatic delivery of required parts and raw materials to the production line. This feature is unattainable by conventional flat warehouses. Additionally, the implementation of an automated three-dimensional warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Replacing manual storage and retrieval with automated aisle stackers, which is both quick and labor-saving. As workers do not need to enter the warehouse, the working environment is greatly improved. 2) Using a computer management system to manage goods significantly enhances management capabilities, making warehouse management more scientific, with substantial improvements in accuracy and reliability. Tasks like inventory management, inventory taking, and reporting become simpler and quicker, greatly reducing labor intensity. 3) The three-dimensional warehouse system is supported by auxiliary conveying equipment at the warehouse entrance, simplifying and facilitating inbound and outbound operations. 4) The automated three-dimensional warehouse system requires minimal staff for operation and system maintenance, saving labor and materials, conserving funds, and improving the working environment, achieving multiple benefits with a single 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 and material management is scattered, making it difficult to achieve close integration between production management and production processes. To reach the expected production capacity and meet production requirements, an adequate supply of raw materials and components is necessary. This leads to a significant issue of inventory capital pressure. 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 of the effective means to address this issue. 1) A factory logistics system centered around automated storage solves the circulation and supply-demand conflicts in various production stages. It allows the supply of raw materials and the production quantity of components to reach an optimal value. 2) The establishment of a computer network system enables more timely and demand-satisfying procurement of raw materials and components. 3) The establishment of a computer management system strengthens macro-control functions, making production quantities in various stages more in line with 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 Modern Enterprises Modern enterprises adopt intensive large-scale production models. This requires close integration of various stages in 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 of the effective measures to achieve this. As previously mentioned, the 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 has become possible for corporate leaders to quickly grasp various material information and for engineers, production managers, and technical personnel to timely understand inventory information for better production process planning and efficiency improvement. The Internet and the company's internal network provide a vast space and solid technical support for online connections, breaking information bottlenecks, broadening horizons, and integrating external and internal resources. Overall, large enterprises both domestically and internationally have gradually adopted automated logistics systems since the 1960s, making it an indispensable part of corporate production management. According to relevant 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.
