Definition

Due to their efficient use of space for storing goods, these warehouses are often metaphorically referred to as "vertical warehouses."

The Automated Storage and Retrieval System (AS/RS) is a revolutionary achievement in logistics technology. Typically composed of high-level shelves, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS), it can automatically store and retrieve 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 employed in AS/RS; in 1963, the U.S. was the first to implement 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, forming a specialized discipline. In the mid-1960s, Japan began to develop AS/RS, with increasing speed, 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 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 Machinery Research 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 incoming and outgoing capabilities, and computerized control management, AS/RS have become an indispensable warehousing technology for enterprise logistics and production management, and are increasingly valued by businesses.

Application

The application scope of automated vertical warehouses is very broad, almost covering all industries. In our country, the main industries applying automated high-rise warehouses include machinery, metallurgy, chemical industry, aerospace, electronics, books, food processing, tobacco, printing, distribution centers, airports, and ports.

Basic Components

The automated three-dimensional storage system is basically 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 (shipping crate): A container used for carrying goods, also known as a work station tool.

4.3 Conveyer Stacker: Equipment used 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 methods: straight-line, curved-line, and transfer vehicle.

4.4 Conveying System: The main peripheral equipment of the automated storage and retrieval system (AS/RS), responsible for transporting goods to or from the stacker. There are many types of conveyors, including roller conveyors, chain conveyors, lifting platforms, distribution carts, hoists, and belt conveyors, among others.

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 in 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 (like ERP systems).

 Superiority

The advantages of an automated vertical warehouse are multifaceted, and for enterprises, they can be reflected in the following aspects:

Space Utilization

5.1 Enhance Space Utilization The initial concept of early three-dimensional warehouses was fundamentally centered around enhancing space utilization and 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 deeper meaning, where conserving land is now linked with energy conservation, environmental protection, and more. Some even consider the space utilization rate as a crucial indicator for evaluating the rationality and advancement of a system. The space utilization of a three-dimensional warehouse is closely tied to its planning. Generally speaking, automated high-rise warehouses have a space utilization rate that is 2-5 times higher than that of ordinary flat warehouses, which is quite significant.

Logistics System

5.2 Facilitates the formation of advanced logistics systems and improves enterprise production management levels. Traditional warehouses are merely places for storing goods, with the primary function of preserving them, representing a "static storage." Automated vertical warehouses, equipped with advanced automated material handling equipment, can not only automatically store and retrieve goods as needed within the warehouse but also integrate organically with production processes outside the warehouse. Through computer management systems and automated material handling equipment, warehouses become a crucial component of the enterprise's production logistics. The storage of externally purchased parts and self-produced production parts in automated warehouses is a step in the entire production process, with short-term storage intended to automatically feed into the next production stage, thus forming an automated logistics system. This is a "dynamic storage" and also a clear technical trend in the development of modern automated warehouses. The aforementioned logistics system is also a subsystem of the overall enterprise production management system (from ordering, necessary design and planning, scheduling and production arrangement, manufacturing, assembly, testing, shipment, 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 demand higher management standards, and the "management brings benefits" mindset has become a consensus among most modern enterprise managers.

Production management is a critical component of corporate administration, encompassing areas such as product planning, production organization, logistics planning, external procurement, product quality, and cost estimation. As a central aspect of the production process, the automated high-bay storage system is almost involved in the entire production management process.

Deposit and withdrawal pace

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 boasts superiorities such as the rapid entry and exit capabilities of the automated high-rise storage. It can quickly and properly store goods in the high-rise storage (warehousing) and also promptly and automatically deliver the required parts and raw materials to the production line. This feature is unattainable by conventional flat warehouses. Moreover, the implementation of the automated three-dimensional warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Using automated aisle stackers to replace manual storage and retrieval, which is both quick and labor-saving. As workers don't need to enter the warehouse, the working environment is greatly improved. 2) Implementing a computer management system for goods management, significantly enhancing management capabilities, making warehouse management more scientific, with improved accuracy and reliability. Tasks like inventory management, inventory taking, and reporting become simpler and quicker, greatly reducing the labor intensity. 3) Supporting the system with auxiliary conveying equipment at the warehouse entrance, making entry and exit operations straightforward and convenient. 4) The automated three-dimensional warehouse system requires few operators and system maintenance personnel, saving both human and material resources, conserving funds, and improving the working environment, achieving multiple benefits at once.

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 meet anticipated production capacity and requirements, sufficient raw materials and components must be prepared, leading to significant inventory accumulation. How to reduce inventory capital pressure and fully meet production needs has become a major issue for large enterprises. The high-bay storage system is one 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, allowing the supply of raw materials and the production quantity of components to reach an optimal value. 2) The establishment of a computer network system makes the procurement of raw materials and purchased components more timely and meets actual demands. 3) The establishment of a computer management system strengthens macro-control functions, making production quantities in each stage more responsive to actual needs. 4) Establishing finished goods and semi-finished goods warehouses addresses temporary inconsistencies in market supply and demand, fully utilizing the company's production potential. 5.5 Symbol of Modern Enterprises Modern enterprises adopt intensive large-scale production models, which require close integration of all stages in the production process to form an organic whole. Production management must be scientific and practical, with decision-making being scientifically based. Establishing an automated high-bay storage system is one powerful measure to achieve this. As previously mentioned, automated logistics systems offer 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, all of which are essential for and sought after by modern enterprises. 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 timely understand inventory information to arrange production processes and improve efficiency. The Internet and corporate intranet provide a vast space and robust technical support for online connections with the outside world, breaking information bottlenecks, broadening horizons, and fostering external and internal connections. In reviewing large enterprises both domestically and internationally, since the 1960s, the adoption of automated logistics systems has gradually become an indispensable part of enterprise production management. According to relevant statistics, Japan has already established over 8,000 automated high-bay warehouses (logistics systems). Establishing an automated high-bay storage system has become one of the important symbols of modern enterprises.