Quickly assembled cable guidance with sensors in storage and retrieval units from ATZ and Raiser

What was needed: Cable guidance for power and data transmission to the mobile operating vehicle of the storage and retrieval unit. Condition monitoring of the cable guidance system.

Requirements: Simple handling, quick and easy installation, maintenance-free, fail-safe

Industry: Material handling

Success for the customer: The autoglide energy chain contributes to the simple installation of the "Storage Bee" storage and retrieval unit by enabling an 88% shorter assembly time compared to conventional cable guides. The system is also virtually maintenance-free, durable and prevents unplanned system failures thanks to its integrated sensor technology.

The increase in demand for smaller online shops is also making itself felt in material handling at small and medium-sized enterprises (SMEs). They are increasingly having to think about having their own high-bay warehouses in order to ensure fast order picking and delivery to customers in their constantly growing warehouses. However, storage and retrieval units (SRUs) are expensive to purchase and present many technical challenges.

The two material handling companies ATZ and Raiser Engineering have joined forces to tackle precisely this problem. The result is the "Storage Bee", an innovative storage and retrieval unit that is largely completed in production and then only needs to be assembled on site at the warehouse. The Storage Bee moves on two rails; a guide at the top of the rack is not necessary.

ATZ and Raiser rely on easy-to-handle components to make fast installation possible. This also applies to the power supply, for example. SRUs often rely on busbar systems to ensure the power supply to the mobile operating vehicle. However, deposits can build up on busbar systems, particularly in dusty rack environments, causing contact faults. Maintenance and monitoring result in high financial costs, which is often a problem, especially for SMEs.

Another challenge: SMEs often do not have the personnel capacity to provide large logistics centres with a large number of staff on a permanent basis. Nevertheless, safety in the process must be guaranteed at all times. If the chain were to fail, the damage to the SRUs and the storage facilities would be immense. The aim was therefore to recognise and rectify faults in the cable guidance at an early stage.

For the horizontal energy supply of the SRU, the companies therefore opted for the autoglide 5 energy chain instead of a busbar system. The special feature: The energy chain does not require a guide trough at all, instead a steel cable is tensioned on the floor. The chain is fastened to the fixed end on one side and to the storage and retrieval unit on the other. A groove in the crossbar, precisely matched to the dimensions of the steel cable, ensures that the chain is securely fixed in place.

Unlike conventional systems with optical data transmission, the energy chain carries a bus cable for data transmission as well as other media as required. Another key advantage of the autoglide 5 over a conductor line is its simple handling and quick and easy installation. Raiser and ATZ install the chain on site at the customer's premises in less than an hour.

The Storage Bee is also equipped with the i.Sense condition monitoring system to detect problems with the cable guidance during operation at an early stage. i.Sense combines energy chain systems with intelligent sensor technology, bringing Industry 4.0 to the storage and retrieval unit. Sensors monitor relevant parameters such as the push/pull forces in the energy chain at all times. If the forces increase too much, i.Sense sends the corresponding data to the SRU, which triggers an error message and stops the chain. This prevents nasty crashes. In addition, i.Sense can measure the wear of the e-chain during operation. If a wear limit is reached, a corresponding message is issued and maintenance can be carried out in good time and with foresight.