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31-Meter Heavy-Duty Stacker Crane AS/RS for Battery Aluminum Foil Warehousing
With the rapid development of automation and information technology, manufacturing enterprises are accelerating their transformation toward intelligent manufacturing. In many factories, production lines become intelligent first. After that, intelligent logistics and warehousing become the next necessary upgrade.
The core value of intelligent warehousing is to use height, automation, and information systems together. By expanding upward, the warehouse can increase storage capacity. By using automated equipment, inbound, storage, and outbound operations can be completed automatically. By applying information systems, materials can be scheduled and controlled more accurately.
This article introduces a 31-meter-level heavy-duty Stacker Crane AS/RS project for finished battery aluminum foil products and explains its design logic, equipment selection, and project results.
The project involved the design, equipment supply, material supply, and installation of an automated warehouse and supporting facilities for finished battery aluminum foil products. The customer planned an annual production capacity of 150,000 tons.
The system was designed with functions including dimension detection, automatic inbound and outbound control, outbound operation guidance, operating status monitoring, automatic fault alarms, and automatic detection of location, status, profile, and safety conditions.
The complete intelligent warehouse logistics system included Stacker Crane racking, Stacker Cranes, conveyor systems, WMS, WCS, interface systems, PLC control cabinets, electrical control systems, and supporting components.
Storage capacity was insufficient. Material searching was difficult without information-based management, leading to manual searching during outbound operations.
Materials were large and heavy. Manual movement was impossible, and multi-layer stacking created significant safety risks for forklift operators.
Record-keeping was weak (paper-based). Wrong receiving and shipping were common. Scattered storage areas made overall management difficult.
The existing warehouse measured 70 m x 40 m, with a height of 12 m. It used floor stacking, storing around 2,500 pallets. Plant roads and loading areas were being used as temporary storage areas due to overflow.
A reliable intelligent warehouse design must begin with demand research. The customer's production rhythm and future growth (3-5 years) were analyzed.
The final building size was designed as 82.5 m in length, 54.48 m in width, and 36 m in total height (clear height 33.428 m).
Levels 1 to 10: 2,500 kg/location
Levels 11 to 14: 1,500 kg/location
Levels 15 to 19: 500 kg/location
The final design provided 13,790 pallet positions. More than 80% of materials could be stored directly, with 2,000 transfer pallets for smaller sizes.
Synchronized Design: AS/RS and civil construction were designed together to improve space utilization and control cost.
Ground Load Challenge: 19 rack levels required high-precision floor load-bearing capacity design for the 31.5 m system.
Compatibility: Special bracket-style racks and transfer carriers were used to handle multiple material specifications.
The Stacker Crane body weight reached21 tons. SEW asynchronous servo motors and MIAS forks were selected for stability. Anti-sway control and video monitoring were integrated.
Challenges with the steel wire rope drum size were solved by optimizing the drum diameter and changing the drum direction to fit within the aisle width.
The project successfully solved the customer's storage capacity shortage and created a stable logistics foundation for large-scale production:
For heavy industrial materials like battery aluminum foil, Warehouse Automation must address heavy-load stability and high-bay safety. This project demonstrates how a carefully designed 31-meter heavy-duty AS/RS can transform limited space into a high-capacity, information-based logistics center.
Battery aluminum foil products can be large, heavy, and storage-intensive. A high-bay AS/RS improves storage capacity within limited land and reduces scattered outdoor or floor-based storage.
The final system achieved 13,790 pallet positions with a high-bay design and different rack load levels for different material weights.
Key challenges include crane body weight, acceleration performance, high-bay stability, steel wire rope drum size, aisle width limits, ground load requirements, and safe operation under heavy loads.
Need a high-bay AS/RS for heavy-load materials?
Contact DELIECNto evaluate rack design, Stacker Crane selection, throughput, and long-term storage capacity.