Automated Storage System for Non-Standard Cast Housing Parts

Introduction

In many manufacturing plants, cast parts from the workshop are irregular in shape and must be placed on dedicated pallets. Traditionally, operators classify, move, stack, and record these parts manually, usually with forklifts and paper-based inventory records.

To solve these issues, an Automated Storage And Retrieval System can connect material handling, cleaning-line transfer, inbound and outbound operations, and inventory management into one controlled process. The result is safer handling, higher turnover efficiency, lower operating cost, and a more intelligent warehouse operation.

Overview of the Cast Housing Parts Storage System

Cast housing parts are typically large, heavy, irregular, and high value. Manual forklift handling creates high labor intensity and operational risk, while traditional storage occupies large floor areas and offers limited visibility.

Considering the handling characteristics of cast housings, the project adopted double-column stacker cranes to improve structural stability and operating reliability. The stacker cranes use vector closed-loop variable-frequency control to support high-speed movement while reducing load instability.

The lifting mechanism uses a brake-equipped spiral bevel gear motor reducer to directly drive the drum. Steel wire ropes drive the load platform up and down. Fixed and movable pulleys are made of engineered nylon, which helps reduce noise and makes maintenance easier. The wire rope is designed with a safety factor of 10, and the customized high-strength wire rope can support stable use for 4 to 6 years.

Integrated AGV Handling and Process Connection

The system uses underride AGVs at warehouse entrances, exits, and key workshop interfaces. Their role is to automatically connect operators, production processes, cleaning lines, and the automated warehouse.

The pallet is then automatically transferred to the storage point. The stacker crane picks it up and stores it in the assigned rack location. During outbound operation, the stacker crane retrieves the pallet, places it onto the conveyor, and transfers it to the exit area for AGV delivery to the assembly workshop.

Software Architecture: WMS, WCS, and RCS

Through these systems, the warehouse can plan storage locations, define process nodes, improve handling efficiency, and record the full operation history of each part. The system tracks production status, assembly status, inbound status, outbound status, and inventory changes in real time.

Key Problems Solved by the System

Design Measures and System Improvements

The pallet design was standardized as much as possible to reduce pallet types and improve compatibility across different housing parts. A four-level automated storage system was built to make better use of vertical space.

WMS automatically assigns storage locations according to product type. Once the pallet reaches the assigned position, inventory information is recorded automatically. During outbound operation, the specified pallet is retrieved and the system automatically deducts the corresponding inventory.

Workflow of the Cast Housing Parts Storage System

Semi-finished cast parts are produced in the casting workshop and moved to the buffer area. A gantry robot transfers the workpiece to the turning machine. Operators use a PDA to scan the barcode and confirm information.

If the parts are finished goods, the AGV transfers the pallet to the cleaning machine inbound docking position. After cleaning, the AGV transfers the pallet to the automated warehouse inbound point. The pallet then passes through profile inspection and barcode identification before the stacker crane stores it in the assigned location.

Safety Measures and Emergency Protection

When the load on the platform exceeds 1.5 times the rated load, or when the wire rope loses tension, the lifting mechanism stops immediately to protect both personnel and equipment.

Project Results

After implementation, the cast housing storage system realized automated connection across production, cleaning, assembly, inbound storage, and outbound operations.

The project reduced manual handling, improved logistics efficiency, reduced high-level stacking operations, enhanced operational safety, and solved the problem of limited storage area.

Conclusion

For large, heavy, and irregular cast housing parts, traditional forklift handling and floor-based storage are no longer sufficient. An automated storage system integrating stacker cranes, AGVs, conveyors, gantry robots, WMS, WCS, and MES can significantly improve safety, storage density, logistics efficiency, and inventory visibility.

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