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| Building Project for Rübsamen GmbH & Co. KG, Bad Marienberg | Deutsch  |
| Automatic High Rise Rack |
The Helmut RÜBSAMEN GmbH + Co. KG company in Bad Marienberg is a company specialising in metal forming by stamping and deep drawing and has been part of the Indus Holding AG group since 2003. Continued growth over the years had forced the company to operate in three separate buildings and further considerable increases in turnover have led to bottle-necks in production, storage and transportation within the plant, so that Unternehmensberatung Dr. Minten GmbH a company consultant, was called in to draw up a concept for expansion and re-organisation that would include materials handling and storage. |
| The high rise rack: Planning |
The first outcome of this concept was a structure for Goods Inwards and Despatch connecting two of the old buildings. This new complex was then connected to the third building by a fully automatic high rise rack.
The high rise racking, which included roof and walls as well as entry and exit conveyor systems, was put out to tender and won by Saar Lagertechnik GmbH. The tender for the stacker crane, the storage control and inventory system was won by LTW Lagertechnik Wolfurt GmbH.
A challenge for all the companies involved in the project was the realisation of the high rise rack in two construction phases. The first phase covered approximately 35% of the total building project. After the new logistic centre had been put into operation, the pallets holding the company’s tooling were put into storage and the old racking taken down. This area was then used to extend the high rise rack. |
| The High Rise Rack: construction/operation |
The high rise rack has three gangways, is 117m long, 13m wide and 9m high. 3,950 caged pallets, Euro-pallets and special pallets for tooling with up to 2,000kg each will be stored. The frames at the end of the racking have been used to install pick-and-deposit stations. The racking is served by a crane stacker able to travel on tracks round bends and operate in a circle.
On the frames at the end of every rack there is a channelled entry/exit station and across one bay three more all consisting of 3-track chain conveyors. In addition there is one station equipped with two chain conveyors for removal. The exit station in Despatch is positioned at right angles for space reasons and has an intermediate storage area for up to eight pallets. As the working area is on a slope, four channelled entry / exit stations have been positioned at the height of the lowest storage level. Saaar Lagertechnik had to build a special structure to compensate for a difference in height of 1,900mm.
When pallets are being put into storage the conveyor system checks the shape of the load, the amount of free space at the bottom and the height of the pallet. This allows the inventory system to pick an appropriate storage space. There are storage levels for pallets with heights of 380, 500, 700, 970 and 1,525mm. At the same time a weighing machine set in the conveyor ascertains the weight of the pallet and compares it to the weight on the master file to find out whether any parts of the tooling are missing.
A special feature of the rack is that the outer rows are narrower. This is necessary because of the slanting support wall. Saar Lagertechnik was also charged with bridging this wide gap, which in places is up to 2m wide, with an inclining roof.
The stacker crane is used not only to store and remove pallets but also for transport between the entry / exit stations in the various departments. All operations in the logistic centre can be observed from a platform built into the P + D station for visitors.
VIDEO: Stacker crane. |
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| Conveyor system: Technical Data |
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| Conveyor system: construction / operation |
In a total of 6 positions there is one entry and one exit section each between the high rise rack and Production. A forklift truck or a high platform truck equipped with a support arm is used to forward the goods and set them down on the P + D station. The report is given manually to the inventory system using a terminal. Registration is then activated with a hand scanner (start of tracing procedure), and the conveyor system automatically set in motion.
After the shape of the goods and the space required for the forks have been checked, the weight is recorded. In the event that one of these values is not within the given tolerances, the goods are declared to be Not In Order and returned to the P + D station. The problem is reported by a lamp and shown graphically at the terminal.
If the tolerances have been maintained, then the goods are forwarded through a fire door (always kept open), through a fast operating shutter (opens and closes every time goods pass through), up to the acceptance position for the stacker crane in the pallet rack. When the telescopic forks automatically accept the goods, the „handshake“ between the conveyor system and the stacker crane takes place (end of tracing procedure).
The exit section runs parallel to the entry section. The stacker crane places the goods on the acceptance position of the conveyor which automatically sets into motion. Transport takes place through both gates to the acceptance position. The goods are collected by forklift truck.
VIDEO: part of the exit section – from stacker crane to acceptance position. Each of the six positions of the entry and exit sections work independently of each other. Over and above this, two positions are allocated to each production area. This guarantees that, even if a position fails, access to the materials in the store remains possible at all times. In addition, the conveyor can be operated manually in the case of a breakdown. |
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We would be very happy to have the opportunity to work on your behalf and are at your disposal any time by telephone or e-mail to answer your questions, till then |
| We remain, |
| Yours sincerely Saar Lagertechnik GmbH |
| Head Office: Saar Lagertechnik GmbH Wiesenweg 2b DE 65812 Bad Soden am Taunus Fon: +49 (0) 61 96 / 56 05 50 Fax: +49 (0) 61 96 / 56 05 99 Web: www.saar-lagertechnik.com Email: info@saar-lagertechnik.com |