How to store more goods within the same warehouse space, achieve more efficient inbound and outbound operations, and create more value and profit has become a question that every warehouse operator must consider. To solve this problem, high-density storage systems have emerged, offering advantages such as high space utilization, flexible operation, and autonomous navigation.
Based on their level of automation, high-density storage systems can be divided into three main categories: fully automated high-density storage systems, semi-automated high-density storage systems, and ordinary high-density storage systems. Based on their functional types, they include: automated high-density storage systems using shuttle carts, four-way shuttle cart systems, multi-level shuttle cart systems, electric mobile racking systems, shuttle cart racking systems, push-back racking systems, gravity flow racking systems, drive-in racking systems, flow racking systems, hand-cranked mobile high-density shelving, cantilever racking, and so on.
Among dense storage system integrators, Shanghai Yinfeng Robotics Co., Ltd. is a leader in the industry. Its product, the mother-daughter shuttle system, is an automated dense storage system composed of shuttle cars, mother shuttle cars, walking tracks, aisle racks, reciprocating elevators, pallet conveying systems, automatic control systems, wireless warehouse control systems (WCS), and warehouse management systems (WMS), which can achieve a perfect combination of dense storage and automation systems.
As a domestic supplier of dense storage equipment and an integrator of automated logistics systems, Shanghai Yinfeng Robotics Co., Ltd.'s products and systems are applied to manufacturing enterprises and logistics center warehouses. It promotes the construction of smart logistics with Internet of Things technology and provides customers with a full-process service integrating solution planning, R&D design, production and manufacturing, installation and commissioning, and after-sales maintenance. Its main products include warehouse logistics control software, warehouse management system, handling robots, automated warehouse conveying system, SAP interface 3D monitoring, etc.
I. Core Technologies
01. Automatic Identification Technology: Utilizing technologies such as RFID and barcodes, this technology enables rapid and accurate identification of goods. It ensures that the system can automatically track and record the location and status of goods during storage and retrieval. 02. PLC Control Technology: A PLC (Programmable Logic Controller) is the core control device of an automated storage system. It receives and executes instructions from the Warehouse Management System (WMS), controlling the operation and status of storage equipment. 03. Data Acquisition and Monitoring Technology: Using sensors, cameras, and other devices, this technology collects real-time operational data and environmental parameters of the storage system. This data is used to monitor the system's status, predict potential problems, and provide data support for optimizing storage strategies. 04. Equipment Scheduling and Control Technology: Advanced scheduling algorithms and control strategies ensure that storage equipment operates efficiently and orderly in busy warehousing environments. These technologies reduce conflicts and waiting times between devices, improving overall storage and retrieval efficiency. 05. Warehouse Management System (WMS) Integration: Dense storage systems are typically integrated with a WMS to achieve comprehensive information management of storage, retrieval, tracking, and management functions. A WMS provides enterprises with key data such as real-time inventory information, order processing status, and supply chain visibility.
II. Key Equipment
1. Automated Storage and Retrieval System (AS/RS): An AS/RS is one of the core pieces of equipment for high-density storage. It achieves rapid storage and retrieval of bins in three-dimensional space through vertical lifts and horizontal moving mechanisms. 2. Shuttle System: Shuttles are commonly used handling equipment in automated storage systems. They can move quickly between racks, transporting goods from one location to another. Depending on the needs, shuttles can be unidirectional, bidirectional, or multidirectional to adapt to different storage scenarios. 3. Lift System: A lift system is a mechanical device used for vertically or inclined lifting of materials or personnel. It includes electric and manual types and consists of the lift body, drive unit, and control system. Widely used in industrial and construction fields, it requires regular maintenance to ensure safety. 4. Conveying and Sorting Equipment: Conveying and sorting equipment is used to transport goods from storage areas to picking or shipping areas. These devices are typically high-speed and efficient, ensuring smooth flow of goods during picking and shipping processes.
III. Advantages of Dense Storage
01. High Space Utilization: The close arrangement of goods reduces wasted space, allowing warehouses to store more items within the same physical space. 02. High Storage and Retrieval Efficiency: Automated or semi-automated storage equipment (such as automated storage and retrieval systems, shuttle systems, etc.) enables fast and accurate storage and retrieval of goods, reducing manual handling and searching time. 03. Good Cargo Protection: High-density storage systems are typically equipped with advanced cargo protection and monitoring systems to ensure the safety of goods and their contents during storage. 04. High Flexibility: High-density storage systems can be flexibly adjusted according to the actual needs and spatial layout of the warehouse, adapting to the storage requirements of different types and quantities of goods. 05. High Level of Informatization: Modern high-density storage systems are usually integrated with a warehouse management system (WMS), achieving comprehensive informatization of cargo storage, retrieval, tracking, and management, improving the transparency and traceability of warehousing operations.
Overview of Automated Intensive Storage and Retrieval Systems
Automated storage and retrieval systems (AS/RS) are advanced automated warehousing systems that combine high-rise racking, stacker cranes, and automated control systems to achieve efficient storage and retrieval of goods. This type of warehouse makes full use of vertical space, significantly increasing storage capacity while reducing labor costs and improving the overall efficiency of logistics operations.
Working principle of automated high-density storage
The working principle of automated storage and retrieval systems (AS/RS) relies primarily on highly automated machinery and intelligent control systems. Stacker cranes move between racks, accurately storing or retrieving goods from designated locations according to instructions from the control system. Simultaneously, advanced warehouse management software enables real-time inventory monitoring, rapid product retrieval, and automatic inventory data updates.
Application scenarios of automated high-density storage systems
Automated storage and retrieval systems (AS/RS) are widely used across various industries, particularly in manufacturing, logistics, and retail, where they offer significant advantages. In manufacturing, they enable rapid storage and turnover of raw materials, semi-finished products, and finished goods. In logistics, they help improve sorting speed and delivery efficiency. In retail, automated AS/RS optimize inventory management, reduce stockouts, and enhance customer satisfaction.
Automated high-density storage and retrieval systems improve logistics efficiency.
The application of automated storage and retrieval systems (AS/RS) has a significant impact on improving logistics efficiency. First, it greatly improves the utilization rate of warehouse space and reduces the waste of land resources; second, through automated operation, it reduces human error and improves operational accuracy; finally, the introduction of intelligent control systems makes warehouse management more convenient and efficient, saving enterprises a significant amount of manpower and time costs.
The core equipment of intelligent warehousing is the automated transportation system.
Automated transport systems are a key component of smart warehousing, encompassing various equipment such as belt conveyors, roller conveyors, and pallet conveyors. The primary function of these systems is to efficiently transport cartons and crates, ensuring that goods reach their designated locations quickly and accurately.
Automatic Storage System
Automated storage systems encompass two core components: automated storage and retrieval systems (AS/RS) and automated high-density storage systems. In AS/RS, stacker cranes are indispensable equipment. Stacker cranes are divided into pallet stacker cranes and box stacker cranes; the former are commonly used in pallet AS/RS, while the latter (such as Miniload) primarily serve box AS/RS. Currently, although there are differences in precision between domestic and international stacker crane technologies, the overall technological gap is not significant. Furthermore, the pallet conveying system in AS/RS, such as multi-level shuttles (including shuttle cars and mother-daughter cars), is also a crucial element in ensuring efficient storage. As for automated high-density storage systems, they primarily serve the storage of boxes, and China is continuously pursuing technological advancements in this field.
Automated sorting system
In recent years, automated sorting systems have attracted much attention, especially in the express delivery industry and e-commerce warehouses. This system can efficiently classify and sort items according to their category, size, or destination, greatly improving logistics and warehousing efficiency. 1) Cross-belt sorting systems and tilting tray sorting systems are mainly suitable for sorting bins and single-item picking operations. 2) Sliding block sorting systems are designed specifically for box sorting. They operate using left-right separating devices (often called swing wheel sorting systems) installed between the belt conveyor and the roller conveyor. 3) Swing wheel sorting systems are also used for box sorting. Their working principle is to separate and sort boxes by using swinging wheels.
Robot sorting system and goods-to-person picking
Robotic sorting systems aim to achieve efficient goods-to-person sorting, with AGVs (Automated Guided Vehicles) being a typical example. This system sorts individual items by placing AGVs on a specific matrix, similar to the operation of a Minions matrix sorting system. Goods-to-person picking systems are a key technology in modern logistics, significantly improving sorting efficiency. There are several types of these systems; we will focus on two in the following sections: 1) Automated horizontal rotary storage: This type of system is mainly used for storing boxed items. However, its disadvantage is that the entire inventory rotates during rotation, resulting in relatively high energy consumption. If the inventory is small, the cost-effectiveness of using this system may not be high, and its cost is relatively expensive. 2) Automated vertical rotary storage: This system is more suitable for sorting small items, such as screws, electronic components, and medicines. In hospital pharmacies, this type of sorting system is often used for the automated sorting of medicines.
