Retrofitting and reprogramming of a storage and retrieval machine and a carousel system

Despite the modernisation measures already carried out, there were considerable disruptions in the production and conveying process. The stacker crane was not correctly synchronised when travelling between the racks, resulting in unstable movements and mechanical loads on the frame. The friction wheels of the load carrier braked asynchronously, which caused blockages and led to high wear and increased maintenance costs, while the visualisation showed incorrect pallet positions - pallets were not recognised correctly, which led to incorrect bookings and unnecessary travel paths for the stacker crane. The transfer to the storage station did not function reliably, end positions were overrun - resulting in damage to the lift gates and the device itself. The control of the operating modes (full/manual/emergency operation) was no longer functional, and there were no emergency options for interrupting the system. The hydraulic motor of the concrete spreader was constantly running, which led to material losses.

Following a detailed analysis and on-site inspection, a comprehensive specification was drawn up. The aim was to largely continue using the existing technology and only modernise it where necessary. As part of the project, HEITEC:

• modernising the drive technology (motors, inverters, synchronisation technology)
• reprogramming the control system including safety functions
• renewal of the visualisation for a clear overview and simple operation
• replacing the control points, control cabinets and obsolete control components (ET200M/Profibus)
• the integration of new sensor technology, e.g. for precise pallet detection during storage and circulation
• the introduction of emergency operation including an emergency stop function for maintenance and safety purposes

A particular focus was placed on ergonomics and user-friendliness. The operator can now switch between automatic and manual mode directly in the control centre. Stations, pallet positions and parameters can be clearly visualised and adjusted as required via new display surfaces. The electrical conversion of the SRM, the circulation system and the concrete spreader was completed in less than two weeks. This was followed by software commissioning, tests and an accompanied ramp-up phase. The project was completed in March 2024 with successful acceptance by the customer.

Customer benefits

• Trouble-free system operation thanks to synchronised drive technology
• Avoidance of blockages, wear and mechanical stress
• Precise visualisation - full transparency of pallet positions
• Modern control technology - future-proof and easy to maintain
• Error messages eliminated, clear diagnostics thanks to optimised sensor technology
• Integrated safety functions, including emergency operation and emergency shutdown
• No unnecessary loss of energy and material thanks to automated shutdown
• Reduced manpower and maintenance requirements
• Fast commissioning and minimised production downtime