Intralogistics and Storage System in a Press Shop in the Automotive Industry

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1 Vollert Anlagenbau GmbH + Co. KG Postfach Weinsberg/Germany Stadtseestr Weinsberg/Germany Telefon +49 (0) 7134 / Telefax +49 (0) 7134 / Project: Intralogistics and Storage System in a Press Shop in the Automotive Industry Seite: 1 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

2 Modern press shops with their high-tech systems are nowadays guarantor for the achievement of highest quality with the subsequent processing of the pressed parts. In the automobile industry metal sheets of different thickness and materials are fully automatically processed at rapid speed from the coil to the finished pressed part, i. e. with insignificant manpower requirements. The following describes a press shop with several press lines in two halls: The whole blank logistics in front of two presses in hall 1 and behind them was required to be planned with a minimum of staff, i. e. without the application of a hall crane or fork stacker. Another requirement was that the conveyor technique connects the existing press hall with existing high-bay warehouse with a second hall and a new high-bay warehouse with preceding coil system. The demands on the conveyor technique and the high-bay warehouse were thoroughly specified and divided in four fields: - conveyor technique for the blank load carriers - high-bay warehouse for the blank load carriers - conveyor technique for the pressed part load carriers - conveyor technique for the scrap disposal For the supply of both presses it is of utmost importance that eight different load carriers are safely moved and stored. Load carrier data: Length mm 2000 to 4100 Width mm 1800 to 2200 Loads t 1 to 20 Seite: 2 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

3 The load carriers reach the circulation by means of three input/output points. Input / output points "external storage on the ground The blanks not manufactured in the press shop reach an external storage place by means of fork stacker. Before the different load carriers are stored into the high-bay warehouse by means of a lifting truck, they are aligned via a mechanical centering device and undergo a subsequent position control. Seite: 3 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

4 Input / output point on the upper floor hall 1 Load carriers with special parts that cannot be stored via external storage by means of fork stacker, are directly taken into the circulation by means of a hall crane hand-over position with centering device. A buffer distance with lifting truck and deposit locations equalizes the AGV load carrier transport to the high-bay warehouse. Seite: 4 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

5 Input / output point on the upper floor hall 2 Produced blanks are inserted into the system on load carriers via fork stackers, such as with the external storage. Core of the total system is the high-bay warehouse system. All input / output points described above are connected by means of an AGV transport system with three vehicles. Also these vehicles were completely supplied by Vollert. Each load carrier, whether fully loaded, partially loaded or empty, is at least handled once by the storage and retrieval system. Seite: 5 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

6 High-Bay Warehouse Conveyor technique for blank pallets Year of construction: 2003 Storage capacity 322 pallets, 4700 t max. Pallet weight 20 t max. Size of pallet 2.2 m x 4,1 m max. Pallet transport in the rack by means of storage and retrieval system: Travel speed 1.5 m/s max. Lifting speed 0.6 m/s max. Pulling-on and pushing-off speed 0.4 / 0.8 m/s Carrying load including pallet 20 t System for the press supply consisting of: AS/RS system with rack, four lifting trucks for storage/release Five load transfer units for loading/unloading of the AGVs Warehouse management system to control the system Average cycle time for a double cycle of the AS/RS system 3 min Seite: 6 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

7 The load carriers located in the press supply system are fully automatically moved from the input points or from the coil system to the high-bay warehouse, from there to the presses and then back again. Load transfer units grip, lift, move and turn the different load carriers. Seite: 7 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

8 With the transfer unit in front of the high-bay warehouse load carriers are for example taken over from the AGV, turned to the appropriate position, placed upon a lifting truck and handed over to the storage and retrieval system of the high-bay warehouse. Seite: 8 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

9 The press supply system is provided with five load transfer units in total. Two of them serve the press tables - also fully automatically. Seite: 9 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

10 Behind the presses the conveyor technique of the pressed part disposal follows the conveyor and storage technique of the press supply. The parts are manually taken off from the pressed part conveyor belts and inserted into load carriers. The operating staff is able to position the load carriers ergonomically by means of a turning device, transfer unit, lifting and tilting device. Alternately, empty load carriers are provided and filled load carriers removed. The conveyor technique for each pressed part disposal consists of four cantilever lifters, longitudinal and cross roller conveyors, angular transfer units, load carrier stacking devices and fork stacker hand over and take over positions. Seite: 10 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

11 load carrier stacking device lifter fork stacker hand over position cross roller conveyor lifting table lifting table with turning device load carrier - pallet longitudinal roller conveyor cross transfer car Seite: 11 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

12 A warehouse management system (LVS) controls the processes in the high-bay warehouse and the complete material handling of the load carriers in both halls. A S DP was applied for the conveyor technique and a CPU-318-2DP for the storage and retrieval system. The warehouse management system was executed as server with Hot-Standby and 3 Clients including visualization. The inferior control connection is effected via Ethernet with TCP/IP interface. Control configuration Seite: 12 Alle Rechte bei Vollert Anlagenbau GmbH + Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberechte bei uns.

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