Automatic Storage and Retrieval Systems (AS/RS)

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Atlas Automatic Storage RetrievalSystems
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PITCH - Servo belt driven
LIFT Servo rack pinion
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Overview
Atlas Automatic Storage and Retrieval Systems
(AS/RS) are the perfect solution for many
stamping operations where growth is exceeding
available pressroom floor space. Just-In-Time
requirements have created the need to keep a
large number of die sets ready and waiting on the
pressroom floor. For contract stampers that have
acquired a larger customer list or OEMs that
have increased their product offering, more
active die sets are crowding operations and
decreasing productivity. By utilizing otherwise
unused vertical space, the need to invest in
plant expansion and additional capital equipment
is alleviated along with the benefit of
increasing press uptime by slashing die change
times by as much as two-thirds. Slow changeover
and floor space problems can create a vicious
cycle for stamping plants that are focused on
short production runs. Consider the scenario of
searching for a die set, maneuvering other items
out of the way to retrieve it, utilizing several
production workers to hook the die to a crane,
perform the die change and then begin production.
For short batch runs, half of the available
production time is lost. If batch time is
increased beyond JIT requirements, then storage
of the parts/blanks becomes an issue and
therefore, more floor space is lost. The more
space that is lost, the higher the risk to damage
dies and parts.
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The Benefits To gain needed capacity and
efficiency many plants are exploring options
other than increasing plant size. Storage and
retrieval systems can be used in many
applications to help alleviate the problems
associated with growth. They provide space and
storage while helping to increase press use,
providing expanded production capabilities
without investing in additional presses and
peripheral automation. An AS/RS accomplishes
this by vertically stacking dies, parts or coils
in storage bays while maintaining fast and
controlled access to them. Average time of
retrieval with an Atlas system is less than 5
minutes and may be accomplished while the press
is in operation Fully automatic retrieval with
the elevating cart is accomplished with a touch
screen user interface. Stored items are fully
accounted for with die or part tracking controls.
All retrieved items are presented to a common
location at the desired time and may be prestaged
on die tables for pick-up via fork truck, crane
or die cart. The retrieval system is fully
guarded which controls access to the system and
protects plant personnel from potential injury.
AS/RS solutions are fully customizable in that
storage bays may vary in size by vertical row.
Systems may range in size from 10 bays up to 1000
bays and may be installed in phases to
accommodate future needs.
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The Atlas Retrieval Cart
Atlas is the only AS/RS manufacturer in the
marketplace with wire rope technology for
virtually unlimited weights. Our standard heavy
duty design is capable of safely transporting and
lifting 60 tons of material per load with ease.
Atlas carts travel at much higher speeds too up
to 100 feet per minute unloaded and 80 feet per
minute with full loads. The advantage of
choosing a wire rope retrieval cart over a
standard ball screw configuration Machining
time for a ball screw of this length is measured
in terms of weeks of downtime. In contrast, wire
rope needs no machining and is immediately
available. The cost of purchasing (4) extra
ball screws to assure quick replacement is
expensive as well as difficult to store. In
contrast, wire rope is inexpensive and easy to
store. The steel for long ball screws is not
readily available and would require larger
purchased quantities than (4) , in contrast wire
rope is readily available. Ball screws are more
susceptible to damage in both emergency stop and
crash conditions occurring from operator error.
Replacing ball screws is difficult and expensive.
In contrast, wire rope systems have some
elasticity so that sudden stops do not result in
such high loads on the rest of the system, and
they are inexpensive and relatively simple to
replace. Wear due to misalignment, lack of
lubrication or excessive loads on a ball screw
will result in potential failure with no warning.
In contrast, wire rope systems will give a
warning of future failure. There is very little
wear on the drums on a wire rope system so only
the rope needs occasional replacement.
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The Objectives
Our customers have based their equipment
acquisition on the following three
objectives First Increase stamping capacity
within existing floor space. This provides more
effective use of existing presses and means that
the space for an AS/RS will be at a premium and
must be minimized. Another portion of this goal
is to reduce inventory on the plant floor by
making smaller part runs more effective. Second
Reduce material handling requirements. This
involves eliminating the use of fork trucks and
overhead cranes for the movement of dies.
Ultimately, the crane should be utilized for
moving coil stock and fork trucks should be used
for moving finished parts and the removal of
scrap. Third Ensure consistent part/blank
quality by protecting dies from damage. Reducing
the handling of dies, especially by fork truck
greatly reduces the likelihood of dropping and
harming them. Automatic Storage and Retrieval
Systems accomplish all of these goals and
increase throughput at the same time.
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How it Works Atlas Automatic Storage and
Retrieval Systems are most effective when used in
conjunction with Atlas die change systems. This
provides for both the movement of the dies or
parts into and out of the storage system and into
and out of the press in a fully automated and
integrated manner. Floor space limitations are
overcome with a series of multi-tier storage rack
units with individual compartments for dies or
parts. Each compartment is accessed by the
elevating retrieval cart. The retrieval cart is
used exclusively for accessing or storing dies or
parts, while the die change equipment is used
exclusively for loading and unloading the
presses. This allows the AS/RS to retrieve the
up coming die set while the press is in
operation. All dies are equipped with
permanently attached, standardized subplates for
uniform handling within the system. Each slot in
the rack is equipped with rollers to facilitate
load and unload. Mechanically actuated retainers
in the rack slots help to ensure safe retention
of the dies. Additionally, the retrieval cart
lift platform is equipped with safety latches
that prevent accidental or unintended lifting or
lowering of the platforms and also ensures the
platform is lined up correctly with the rack slot
before die removal begins. Once the die is
retrieved, it is placed onto a die table where it
is pre-staged and waiting for the next die change
sequence. The die cart (non-elevating) that
services the press would remove the out going
die, transport it to an empty die rack and
deposit it for pick-up by the storage and
retrieval cart. The die cart would then move to
the rack with the incoming die, pull it onto the
cart and transport it to the press for insertion.
A full die change sequence can occur within less
than 3 minutes.
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• Reasons to Install an AS/RS
• Better use of floor space is the main reason for
  installing a multi-level AS/RS. Other reasons
  include
• Improved part quality. The AS/RS that works in
  conjunction with dedicated die change equipment
  allows the operator to move dies or parts in a
  controlled manner that virtually eliminates die
  damage from handling. Dies that stay in top
  condition translate into consistently higher
  quality parts due to maintaining their original
  tolerances.
• Reduced die repair costs. Because dies are
  handled in a safe and controlled manner, the need
  for repair and replacement decreases.
• Improved safety. Because the die movement is
  controlled, the possibility of dropping a die or
  putting an operator in a dangerous situation is
  greatly reduced.
• Increased production. This derives from two
  factors. First, when changeover time is reduced,
  press uptime increases and more parts are
  produced. Second, the quality of the first off
  parts allow the stamper to run more parts per
  batch without the downtime that is associated
  with quality problems.
• More effective production control. With an AS/RS
  it is easier to schedule production runs because
  the retrieval of the next required die set is
  completely controlled. In emergency batch run
  situations, such as an unscheduled part that
  needs to be run immediately, the process of
  changeover is efficient and not dependent on the
  availability of general plant material handling
  personnel and the equipment required to move the
  die such as fork trucks and cranes.

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• Economic Justification
• Points to keep in mind when considering an AS/RS
  system and planning the economic justification of
  the equipment should include the following
• The costs to add more plant space to continue the
  current storage methods
• The costs of the current material handling
  equipment, maintenance and labor
• The time that is lost due to part quality
  problems
• The cost of die repair and replacements because
  of the current handling methods
• The cost of safety issues (insurance, lost work
  time, etc)
• Profits that are lost because of press downtime,
  such as unnecessary over time and reduced
  production
• Inventory costs from running large lot sizes
  instead of being able to run Just-In-Time

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Specifications Options
Controlled Transfer Variable Speed Loaded
Up to 80 fpm Unloaded Up to 100 fpm Lift
Speed Loaded Up to 50 fpm Unloaded
Up to 100 fpm Simultaneous lift and travel
functions Storage Bays 10 to 1000 Storage
Size Customer specified Maximum
Weight None Options Automatic load
weighing Managed die tracking Automatic press
loading/unloading of the die to/from the
system Ball screw or wire rope lift design PC
based remote access diagnostics via modem Front
office control package
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Die Handling Automation Robotic Integration
Sheet Metal Handling Tri-Axis Transfers System
Integration AS/RS Washer Oiler Systems
Automation Tooling
Why Atlas? Our Promise.Atlas listens to you,
the customer. We embrace your vision and
understand your motivation. Its our culture of
total commitment that allows us to conceptualize
solutions tailor made to fit your specific
applicationscreating world class material
handling systems that will exceed your
expectations.
3100 Copper Avenue Fenton, Michigan 48430
USA Phone [phone] Fax 1
810.629.8145 www.atlastechnologies.com