AutoStore: Space saving storage and order picking system for small parts

AutoPiQ combines the power of AutoStore with the perfection of intelligent robotics. The robot can be installed at ports (here port-to-port picking, for example for pre-picking). Via video system, different items are detected and suitable gripping points for picking are automatically determined.

The advantages:

• Reduced dependence on human labour
• Uncomplicated handling of order peaks
• Easier order processing through pre-picking, e.g. overnight
• Fewer returns due to higher accuracy
• Seamless integration with any WM system

The AutoStore Black Line is the high-performance robot. Like the Red Line, it rides on top of the system and uses lifting belts and a gripper plate to retrieve the required bins from the grid.

Compared to the Red Line, it is about half the size and thus requires less space on the grid. The containers are picked up in the robot body. Thanks to its lower weight and innovative drive technologies, Black Line can accelerate and travel faster than the Red Line. With the Black Line, higher robot densities and throughput are thus possible in the same space.

By using a taller housing, the Black Line can transport also the tallest 425 mm bin.

Through the so-called AutoStore Transfer Ports, QuickMove conveyor technologies from Swisslog are directly integrated with AutoStore. This means that picking workstations would not necessarily have to be positioned directly on the AutoStore system. To facilitate packing operations, Swisslog also creates a smooth transition to third-party trades with light goods conveyors, such as:

• Carton erectors
• Carton sealer
• Carton lidding machines
• Labellers
• Scales
• Palletizer

Like all standard AutoStore ports, the conveyor port can be used to putaway or retrieve products. Swisslog's software-controlled pick-by-light functions provide additional guidance to employees.

The aluminium grid is the basic structure of AutoStore and determines the storage capacity of the system. It holds the totes in place and is also the track for the robots. On top of the grid, travel rails run in the X and Y directions so that the robots can access the storage positions within the grid.

Whether a storage container is loaded with just a single item or thousands of very small parts depends solely on the individual requirements. For easier handling, the interior of the storage bins can be further customized with lengthwise and crosswise dividers. With a uniform footprint, three types of containers are available in different heights.

All standard AutoStore ports can be used for putaway or retrieve products. 

To ensure that orders reach the recipient even faster, AutoStore workstations can be optimized with additional technologies. Swisslog SynQ or SAP EWM software guides pickers through the picking process by means of highly user-friendly dialogs.

Pick-by-Light (light beam indicates the pick compartment and light spot indicates the destination bin) additionally guides the employees. This increases picking accuracy and speed, and employees are quickly trained.

Our software solutions optimize the hit rate in batch picking by grouping orders and their order positions. In this way, orders can be processed faster in parallel by means of an algorithm, and unnecessary transports of AutoStore bins can be minimized.

Destination totes or cartons are placed directly on mobile carts or passed on by conveyors for packing or shipping. 

The lifting belt cleaning station developed by Swisslog is mounted on the service platform outside the grid. Robots can thus be conveniently pushed in on the rails.

By controlled lowering of the robot's gripper plate inside the framed cell, the lifting straps can be manually controlled and quickly cleaned. Thanks to the special device, cleaning is faster and without crumpling of the lifting straps, which increases the service life of the robot.

The workhorse of the AutoStore system is the standard Red Line robot. Like the Black Line, it rides on top of the system and uses lifting straps and a gripper plate to retrieve the required totes from the grid. The Red Line R5 is compatible with 220 and 330mm height bins. In 2022, the higher R5+ robot model was launched and it is compatible with all three bin types.

With its 8 wheels, it moves on the rails of the grid to the picking ports or to the loading station.

Powered by 12-volt lead-acid batteries, the RedLine robot travels at 3.1m/s.

Seismic activity in various parts of the world might cause problems with AutoStore, compromising the straight rails or possibly the grid's stability. But thanks to aseismic grid structures designed by Swisslog, the system has increased resilience in the event of seismic activity. 

Swisslog's aseismic towers offer seamless integration with the Autostore grid, and have been proven in a number of installations in high seismicity zones. The seismic grid structures offer increased protection from local seismic activity without impacting the performance of AutoStore or hindering future system expansion plans. 

Depending on the mechanical properties of the flooring, the pitch between the towers and the anchor type can be adjusted to account for local seismic activities. 

The sensor cleaning station was specially developed by Swisslog. It is fixed in the grid in a cell. The robots move over the cell and the sensors, which the robots need for path measurements, are cleaned of dust. This allows the robots to perform better for longer.

In addition, fewer manual cleanings are necessary. Overall, this minimizes the customer's maintenance costs.

The service platform is the standard maintenance platform that every AutoStore system needs. From here, the robots can be called up and conveniently driven into the service area for cleaning or maintenance via the service hatch.

Service technicians can also access the grid via the hatch for maintenance. 

SynQ links AutoStore control functions with customer-specific components such as existing ERP, WMS and MFCS installations or automated material flow control system solutions (conveyors, pallet systems, AGVs, etc.). Quick and easy to set up, SynQ synchronizes and optimizes all warehouse processes and creates absolute transparency at all levels and in real time.

SynQ from Swisslog

• A field-proven platform with well over 400 customer installations
• Compatible with all common third-party ERP systems
• Cloud-based as well as on-premise deployable
• Modular design with unlimited extendibility

SAP EWM

By linking AutoStore with SAP EWM, Swisslog paves the way for a holistic material fl ow control with a wide range of functions. SAP EWM can be easily and seamlessly integrated into existing SAP structures - as a decentralized system or embedded in SAP S/4 HANA environments.

Swisslog’s services as an SAP Silver Partner include, among others

• Integration of data generated by AutoStore into the functionality of SAP EWM
• Migration SAP WM to SAP EWM
• EWM implementation fully integrated into warehouse processes with or without automation technology
• Creation of EWM templates for customers with multiple locations to standardize logistics processes across the company
• 24/7 support (Level 2 & 3) for all SAP EWM managed processes (in-house and third-party systems)