Automated storage and retrieval system#Horizontal carousels

{{Short description|Robotic warehouse for physical objects}}

{{Multiple issues|{{more citations needed|date=August 2018}}}}

Image:Automated Storage and Retrieval System - Defense Visual Information Center · DD-ST-96-00253.JPEG, used for the storage of media items such as film canisters]]

Image:Miniload ASRS.jpg

An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations.{{cite web|title=Material Handling Industry of America - Glossary - Page 2 |url=http://www.mhi.org/glossary?fq=title-first-letter%3Aa-c&page=2&sort=title-sort%20asc%2Ccompany-sort%20asc|access-date=17 August 2018}} Automated storage and retrieval systems (AS/RS) are typically used in applications where:

  • There is a very high volume of loads being moved into and out of storage
  • Storage density is important because of space constraints
  • No value is added in this process (no processing, only storage and transport)
  • Accuracy is critical because of potential expensive damages to the load

An AS/RS can be used with standard loads as well as nonstandard loads,{{cite web|title=AS/RS|url=http://www.jervisbwebb.com/Categories/AutoStorRetr.aspx?cid=4|access-date=31 August 2011|archive-date=10 August 2011|archive-url=https://web.archive.org/web/20110810220344/http://www.jervisbwebb.com/Categories/AutoStorRetr.aspx?cid=4|url-status=dead}} meaning that each standard load can fit in a uniformly-sized volume; for example, the film canisters in the image of the Defense Visual Information Center are each stored as part of the contents of the uniformly sized metal boxes, which are shown in the image. Standard loads simplify the handling of a request of an item. In addition, audits of the accuracy of the inventory of contents can be restricted to the contents of an individual metal box, rather than undergoing a top-to-bottom search of the entire facility, for a single item.

They can also be used in self storage places.{{Citation |title=Self storage. Specification for self storage services |url=http://dx.doi.org/10.3403/30167611u |publisher=BSI British Standards |doi=10.3403/30167611u |access-date=2022-12-23}}

Overview

Image:Regalbediengerät.automatisch.kurvengängig.zweimastig.Teleskopgabel.Euro.jpg

Image:Robot book fetcher at University of Utah.jpg

AS/RS systems are designed for automated storage and retrieval of parts and items in manufacturing, distribution, retail, wholesale and institutions.{{Cite web |url=http://www.egeminusa.com/pages/WDS/WDS_ASRS.html |title=Automated Storage and Retrieval (AS/RS) with Cranes |website=egemin automation |access-date=April 22, 2022 |archive-url=https://web.archive.org/web/20150205172920/http://www.egeminusa.com/pages/WDS/WDS_ASRS.html |archive-date=2015-02-05}} They first originated in the 1960s, initially focusing on heavy pallet loads but with the evolution of the technology the handled loads have become smaller.{{cite web|title=Shuttle technology is taking off|url=http://www.mmh.com/article/automated_storage_shuttle_technology_is_taking_off|access-date=11 February 2014}} The systems operate under computerized control, maintaining an inventory of stored items. Retrieval of items is accomplished by specifying the item type and quantity to be retrieved. The computer determines where in the storage area the item can be retrieved from and schedules the retrieval. It directs the proper automated storage and retrieval machine (SRM) to the location where the item is stored and directs the machine to deposit the item at a location where it is to be picked up. A system of conveyors and or automated guided vehicles is sometimes part of the AS/RS system. These take loads into and out of the storage area and move them to the manufacturing floor or loading docks. To store items, the pallet or tray is placed at an input station for the system, the information for inventory is entered into a computer terminal and the AS/RS system moves the load to the storage area, determines a suitable location for the item, and stores the load. As items are stored into or retrieved from the racks, the computer updates its inventory accordingly.

The benefits of an AS/RS system include reduced labor for transporting items into and out of inventory, reduced

inventory levels, more accurate tracking of inventory, and space savings. Items are often stored more densely than in systems where items are stored and retrieved manually.{{cite web|title=AS/RS|url=http://www.daifukuamerica.com/products/3/12//Manufacturing-Distribution/Automated-Storage-Retrieval-System-AS-RS|publisher=Daifuku America|access-date=23 August 2011|archive-date=14 August 2011|archive-url=https://web.archive.org/web/20110814211706/http://www.daifukuamerica.com/products/3/12//Manufacturing-Distribution/Automated-Storage-Retrieval-System-AS-RS|url-status=dead}}

Within the storage, items can be placed on trays or hang from bars, which are attached to chains/drives in order to move up and down. The equipment required for an AS/RS include a storage & retrieval machine (SRM) that is used for rapid storage and retrieval of material. SRMs are used to move loads vertically or horizontally, and can also move laterally to place objects in the correct storage location.

The trend towards Just In Time production often requires sub-pallet level availability of production inputs, and AS/RS is a much faster way of organizing the storage of smaller items next to production lines.

The Material Handling Institute of America (MHIA), the non-profit trade association for the material handling world, and its members have categorised AS/RS into two primary segments: Fixed Aisle and Carousels/Vertical Lift Modules (VLMs). Both sets of technologies provide automated storage and retrieval for parts and items, but use different technologies. Each technology has its unique set of benefits and disadvantages. Fixed Aisle systems are characteristically larger systems whereas carousels and Vertical Lift Modules are used individually or grouped, but in small to medium-sized applications.

A fixed-aisle AS/R machine (stacker crane) is one of two main designs: single-masted or double masted. Most are supported on a track and ceiling guided at the top by guide rails or channels to ensure accurate vertical alignment, although some are suspended from the ceiling. The 'shuttles' that make up the system travel between fixed storage shelves to deposit or retrieve a requested load (ranging from a single book in a library system to a several ton pallet of goods in a warehouse system). The entire unit moves horizontally within an aisle, while the shuttles are able to elevate up to the necessary height to reach the load, and can extend and retract to store or retrieve loads that are several positions deep in the shelving. A semi-automated system can be achieved by utilizing only specialized shuttles within an existing rack system.

File:TGW-Stingray-Shuttle.jpg

Another AS/RS technology is known as shuttle technology. In this technology the horizontal movement is made by independent shuttles each operating on one level of the rack while a lift at a fixed position within the rack is responsible for the vertical movement. By using two separate machines for these two axes the shuttle technology is able to provide higher throughput rates than stacker cranes.{{cite web|title=Stingray Shuttle Solution |url=http://www.tgw-group.com/at-en/services-solutions/order-fulfillment/storage-solutions/stingray-shuttle-solution/ |publisher=TGW Logistics Group |access-date=11 February 2014 |url-status=dead |archive-url=https://web.archive.org/web/20140222232459/http://www.tgw-group.com/at-en/services-solutions/order-fulfillment/storage-solutions/stingray-shuttle-solution/ |archive-date=22 February 2014 }}

Storage and Retrieval Machines pick up or drop off loads to the rest of the supporting transportation system at specific stations, where inbound and outbound loads are precisely positioned for proper handling.

In addition, there are several types of Automated Storage & Retrieval Systems (AS/RS) devices called Unit-load AS/RS, Mini-load AS/RS, Mid-Load AS/RS,{{cite news |url=http://www.mhi.org/media/news/12234 |title=ISD - Integrated Systems Design Announces New UltraStore ASRS Provides Cost Effective Pallet, Case and Item Picking For Operations |access-date=1 July 2013}} Vertical Lift Modules (VLMs), Horizontal Carousels and Vertical Carousels. These systems are used either as stand-alone units or in integrated workstations called pods or systems. These units are usually integrated with various types of pick to light{{Definition needed|date=June 2019}} systems and use either a microprocessor controller for basic usage or inventory management software. These systems are ideal for increasing space utilization up to 90%, productivity levels by 90%, accuracy to 99.9%+ levels and throughput up to 750 lines per hour/per operator or more depending on the configuration of the system.

Horizontal carousels

File:Automated packing.jpg

Robotic Inserter/Extractor devices can be used for horizontal carousels. The robotic device is positioned in the front or rear of up to three horizontal carousels tiered high. The robot grabs the tote required in the order and often replenishes at the same time to speed up throughput. The tote(s) are then delivered to a conveyor, which routes it to a work station for picking or replenishing. Up to eight transactions per minute per unit can be done. Totes or containers up to 36" x 36" x 36" can be used in a system.

On a simplistic level, horizontal carousels are also often used as "rotating shelving". With simple "fetch" command, items are brought to the operator and otherwise wasted space is eliminated.

AS/RS Applications: Most applications of AS/RS technology have been associated with warehousing and distribution operations. An AS/RS can also be used to store raw materials and work in process in manufacturing. Three application areas can be distinguished for AS/RS: (1) Unit load storage and handling, (2) Order picking, and (3) Work in process storage. Unit load storage and retrieval applications are represented by unit load AS/RS and deep-lane storage systems. These kinds of applications are commonly found in warehousing for finishing goods in a distribution center, rarely in manufacturing. Deep-lane systems are used in the food industry. As described above, order picking involves retrieving materials in less than full unit load quantities. Minilpass, man-on board, and items retrieval systems are used for this second application area.

Work in process storage is a more recent application of automated storage technology. While it is desirable to minimize the amount of work in process, WIP is unavoidable and must be effectively managed. Automated storage systems, either automated storage/retrieval systems or carousel systems, represent an efficient way to store materials between processing steps, particularly in batch and job shop production. In high production, work in process is often carried between operations by conveyor system, which this serve both storage and transport functions.

= Inventory Category-specific AS/RS =

Each inventory{{Citation |title=Inventory |date=2025-03-26 |work=Wikipedia |url=https://en.wikipedia.org/wiki/Inventory |access-date=2025-04-04 |language=en}} category—raw materials, work-in-process, and finished goods—requires its own specialized Automated Storage and Retrieval System (AS/RS). Particularly for work-in-process (WIP) inventories, due to variations in manufacturing processes, the AS/RS systems are significantly different in design and function, tailored specifically to match unique handling, storage, and retrieval requirements

=Installed applications=

Installed applications of this technology can be wide-ranging. In some libraries, such as at University of Nevada, Reno library, such a system is employed to retrieve books. Still others in use involve retrieval of bicycles from a bicycle tree, as in the case of systems in Japan.

=Institutions using automated storage and retrieval systems=

Some examples of academic institutions using automated storage and retrieval systems are;

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  • University of British Columbia, Vancouver, British Columbia{{cite web |url=http://services.library.ubc.ca/borrowing-services/asrs/ |title=Access Storage (ASRS/PARC) |website=The University of British Columbia |access-date=April 22, 2022}}
  • California State University, Long Beach, Long Beach, California{{cite web |url=https://www.csulb.edu/university-library/orca-automated-retrieval-system |title=ORCA Automated Retrieval System |website=California State University: Long Beach University Library |date=24 May 2017 |access-date=April 22, 2022}}
  • California State University, Northridge, Northridge, California{{cite web |url=http://library.csun.edu/About/ASRS |title=Automated Storage and Retrieval System (AS/RS) |website=CSUN |access-date=April 22, 2022}}{{cite book |chapter-url=https://books.google.com/books?id=tg78Nmvk7ioC&q=sustained+upheaval&pg=PA101 |first=Susan E. |last=Parker |chapter=Sustained upheaval: Rebuilding the Oviatt Library after the Northridge earthquake |title=Comprehensive Guide to Emergency Preparedness and Disaster Recovery |pages=99 |date=2010 |publisher=Assoc of Cllge & Rsrch Libr |isbn=9780838985489 |access-date=April 22, 2022}}
  • University of Central Florida, Orlando, Florida{{cite web |url=https://library.ucf.edu/21st/arc/ |title=Automated Retrieval Center (ARC) |website=UCV Libraries |access-date=April 22, 2022 |archive-date=November 20, 2021 |archive-url=https://web.archive.org/web/20211120080648/https://library.ucf.edu/21st/arc/ |url-status=dead }}
  • Chicago State University, Chicago, Illinois{{cite web |url=http://csu.libguides.com/services/circulation/rover |title=Circulation: Automated Storage and Retrieval System (Rover) |website=Gwendolyn Brooks Library |access-date=April 23, 2022 |archive-date=August 12, 2021 |archive-url=https://web.archive.org/web/20210812042152/http://csu.libguides.com/services/circulation/rover |url-status=dead }}
  • University of Chicago, Chicago, Illinois{{cite magazine |url=https://www.wired.com/2011/05/robot-powered-mansueto-library/ |title=Robots Retrieve Books in University of Chicago's New, Futuristic Library |last=Watercutter |first=Angela |date=May 11, 2011 |magazine=Wired |access-date=April 23, 2022}}
  • Colgate University, Hamilton, New York{{cite web |url=https://cul.colgate.edu/about-libraries |title=About the Colgate University Libraries |website=Colgate University |access-date=April 23, 2022}}
  • Cornell University, Ithaca, New York{{cite web |url=https://annex.library.cornell.edu/ |title=Welcome to the Library Annex |website=Cornell University Library |access-date=April 23, 2022}}
  • Defense Visual Information Center, March Air Reserve Base, Riverside County, California
  • Eastern Michigan University,{{Cite web |url=http://www.emich.edu/library/services/storage.php |title=Get items from ARC |access-date=2017-02-25 |archive-url=https://web.archive.org/web/20170225135618/http://www.emich.edu/library/services/storage.php |archive-date=2017-02-25 |url-status=dead }} Ypsilanti, Michigan
  • Georgia Southern University, Statesboro, Georgia{{cite web |url=http://news.georgiasouthern.edu/2006/09/26/unique-automated-system-helps-library-deal-with-storage-issues/ |title=Unique automated system helps library deal with storage issues |date=September 26, 2006 |website=Georgia Southern University |access-date=April 23, 2022}}
  • Grand Valley State University,{{Cite web |url=https://gvsuliblabs.com/status/detail.php?system=14 |title=ASRS status |access-date=2017-02-25 |archive-url=https://web.archive.org/web/20170226051131/https://gvsuliblabs.com/status/detail.php?system=14 |archive-date=2017-02-26 |url-status=dead }} Grand Rapids, Michigan
  • Liberty University, Lynchburg, Virginia{{cite web |url=https://www.liberty.edu/library/about/technologies/ |title=Technologies |website=Jerry Falwell Library |access-date=April 23, 2022}}
  • University of Limerick,{{Cite web |last=Halloran |first=Cathy |date=June 22, 2018 |title=New €31m library opens at University of Limerick |website=RTÉ.ie |url=https://www.rte.ie/news/munster/2018/0622/972497-glucksman-library-limerick/ |language=en |access-date=April 22, 2022}} Limerick (Ireland)
  • University of Louisville, Louisville, Kentucky{{cite web |url=https://library.louisville.edu/ekstrom/tour/rrs |title=Robotic Retrieval System |website=U of L University Libraries |access-date=April 23, 2022}}
  • Macquarie University,{{Cite web |url=http://www.announcements.mq.edu.au/library/your_library_on_the_move |title=Your library on the move |access-date=2017-02-25 |archive-url=https://web.archive.org/web/20170226142434/http://www.announcements.mq.edu.au/library/your_library_on_the_move |archive-date=2017-02-26 |url-status=dead }} Sydney, Australia
  • Marywood University,{{Cite web |url=http://100.marywood.edu/print/LC_brochure2014single.pdf |title=Access to the Knowledge Bar |access-date=2017-02-25 |archive-url=https://web.archive.org/web/20170226130917/http://100.marywood.edu/print/LC_brochure2014single.pdf |archive-date=2017-02-26 |url-status=dead }} Scranton, Pennsylvania
  • University of Missouri–Kansas City, Kansas City, Missouri{{cite web |url=https://info.umkc.edu/rooconnection/meet-roobot/ |title=Meet RooBot! |date=October 5, 2010 |website=UMKC Division of Student Affairs |access-date=April 23, 2022}}
  • University of Nevada, Las Vegas{{Cite web |url=https://www.library.unlv.edu/services/lasr-faq.html |title=Lied Automated Storage And Retrieval Unit |access-date=2017-02-25 |archive-date=2017-02-25 |archive-url=https://web.archive.org/web/20170225134907/https://www.library.unlv.edu/services/lasr-faq.html |url-status=dead }}
  • University of Nevada, Reno{{cite web |url=https://www.youtube.com/watch?v=_kz6N1de7lE |title=University of Nevada - Reno library robot |date=May 18, 2009 |publisher=Guido Romeo |website=YouTube |access-date=April 23, 2022}}
  • UTS Library, University of Technology Sydney{{Cite web |url=http://www.lib.uts.edu.au/future-library/project |title=Project |website=UTS: Library |access-date=April 22, 2022 |archive-url=https://web.archive.org/web/20170503182918/http://www.lib.uts.edu.au/future-library/project |archive-date=May 3, 2017}}
  • North Carolina State University, Raleigh, North Carolina{{cite web |url=http://www.lib.ncsu.edu/huntlibrary/bookBot |title=Hunt Library bookBot |website=NC State University Library |access-date=April 23, 2022}}
  • Santa Clara University, Santa Clara, California{{cite web |url=https://www.scu.edu/library/ars/ |title=Automated Retrieval System (ARS) |website=Santa Clara University Library |access-date=April 23, 2022}}
  • Sonoma State University, Rohnert Park, California{{cite web |url=http://library.sonoma.edu/about/building/ars |title=Automated Retrieval System |website=Sonoma State University |access-date=April 23, 2022}}
  • Tri-County Technical College, Pendleton, South Carolina
  • University of Utah, Salt Lake City, Utah{{cite web |url=http://www.lib.utah.edu/services/automated-retrieval-center.php |title=ARC (Automated Retrieval Center) |website=J. Willard Marriot Library: The University of Utah |access-date=April 22, 2022}}
  • Utah State University, Logan, Utah{{cite web |url=https://distance-educator.com/utah-state-university-library-automates-storageretrieval-of-15-million-books/ |title=Utah State University Library Automates Storage/Retrieval of 1.5 Million Books |date=June 17, 2005 |website=Distance Educator |access-date=April 23, 2022}}
  • Christopher Center, Valparaiso University, Valparaiso, Indiana{{cite web |url=https://www.youtube.com/watch?v=gPzT4Sb9ldo |title=Christopher Center AS/RS |date=December 2, 2011 |publisher=ValpoLibrary |website=YouTube |access-date=April 23, 2022}}
  • Waseda University, Tokyo (Japan)

{{colend}}

Types

  • Vertical Lift Storage Modules (VLSM) - These are also called vertical lift automated storage/retrieval systems. All of the next AS/RS types are designed around a horizontal aisle. The same principle of using a center aisle to access loads is used, except that the aisle is vertical. Vertical lift storage modules, some with heights of 10 meters or more, are capable of holding large inventories while saving valuable floor space in the factory.
  • Unit load stackers - The unit load stackers is typically a large automated system designed to handle unit loads stored on pallets or in other standard containers. The system is computer controlled, and the S/R machines are automated and designed to handle the unit load containers.
  • ASRS Gantry Robots - These are a type of Automated Storage/Retrieval Systems used in warehousing and logistics sectors. Some common uses for these are in the Tire Industry for stacking tire inventory. Most of these systems span 50–60 ft in width and average 200–300 feet in length. These systems use End Effectors a.k.a. End of Arm Tooling to pick and place the tire stacks from conveyors.{{Cite web|url=http://sagerobot.com/robotic-ssr|title = Sage Automated Storage and Retrieval System| date=30 August 2018 }}

Man-aboard systems

A man-aboard system can provide significant floorspace savings over manual or forklift operations but is not truly an AS/RS, as the operation is still manual. Storage system heights are not limited by the reach height of the order picker, as the picker rides along on the platform as it is moved vertically or horizontally to the various storage locations. Shelves or storage cabinets can be stacked as high as floor loading, weight capacity, throughput requirements, and/or ceiling heights will permit. Man-aboard storage and retrieval systems are far and away the most expensive picker-to-stock equipment alternative but are less expensive than a fully automated system. Aisle-captive storage/retrieval machines reaching heights up to {{Convert|40|ft|m}} cost around $125,000. Hence, there must be enough storage density and/or productivity improvement over cart and tote picking to justify the investment. Also, because vertical travel is slow compared to horizontal travel, typical picking rates in man-aboard operations range between 40 and 250 lines per person-hour. The range is large because there is a wide variety of operating schemes for man-aboard systems. Man-aboard systems are typically appropriate for slow-moving items where space is fairly expensive.

Workforce automation

In the second decade of the 2000s, the first robotic models appeared on the market equipped with upper and lower limbs (rather than a trolley with a mechanical arm), radar/computer vision or sensors, and capable of recognizing the products, carrying out loading and unloading operations from the truck/shelves/forklifts, positioning the load units on the shelves, handling and picking of the order.{{cite web|url=https://www-wired-it.translate.goog/attualita/tech/2021/03/31/boston-dynamics-strecht-robot-magazziniere/?_x_tr_sl=it&_x_tr_tl=en&_x_tr_hl=it&_x_tr_pto=wapp|title=The warehouse robot that does not need to be trained|date=31 March 2021|language=it}}{{cite web|url=https://www.agi.it/associazione/news/2022-11-12/sparrow-warehouse-robot-amazon-18803598/|title=Here is Sparrow, Amazon's robot warehouse worker who recognizes products|date=12 November 2022|language=it}}{{cite web|url=https://www-liberta-it.translate.goog/news/green-future/2022/10/20/i-nuovi-robot-magazzinieri-si-muovono-e-sono-capaci-di-usare-anche-le-mani/?_x_tr_sl=it&_x_tr_tl=en&_x_tr_hl=it&_x_tr_pto=wapp|title=The new warehouse robots move and are also capable of using their hands|date=20 October 2022}}{{cite web|url=https://www-logisticamente-it.translate.goog/Articoli/13560/boston-dynamics-lancia-stretch-il-robot-magazziniere/?_x_tr_sl=it&_x_tr_tl=en&_x_tr_hl=it&_x_tr_pto=wapp|title=

Logistics 4.0: Boston Dynamics launches Stretch, the warehouse robot|date=

31 March 2021}}{{cite web|url=https://www-wired-it.translate.goog/article/robot-robee-oversonic-startup/?_x_tr_sl=it&_x_tr_tl=en&_x_tr_hl=it&_x_tr_pto=wapp| title=The robot made in Italy that will do the jobs that people don't deserve to do|date=October 23, 2023}}

See also

References

{{Reflist}}

Further reading

  • Frazelle, E. (2001), World-class Warehousing and Material Handling, McGraw-Hill, New York, NY.
  • {{cite web|url=http://mansueto.lib.uchicago.edu/shelving.html|title=Automated Storage and Retrieval System|publisher=The University of Chicago Library|access-date=9 January 2013}}