Classic automated small parts warehouse with storage and retrieval machine

What components does an AKL with RGB consist of?

The main components are:

Racking system: Racking systems for single to multiple-deep storage (single or multiple storage locations) of various load carriers such as containers, trays or cartons.

Storage and retrieval unit (RGB): The RGB is the core of the miniload and moves both horizontally and vertically in the aisles of the miniload. It carries out the storage and retrieval of bins, cartons or trays.

Load handling attachment (LAM): Is a mechanical unit on the storage and retrieval machine that is used to safely grip, pick up and set down storage containers, trays or cartons within the automated small parts warehouse.

Conveyor technology: In the periphery of the warehouse, an infeed and outfeed conveyor system transports the load carriers to the corresponding work stations.

Control and IT components: These include programmable logic controllers (PLC), material flow computers (MFC), warehouse management software (WMS) and connections to adjacent or higher-level systems such as ERP or similar.

What specific advantages does an AKL with RGB offer?

Warehouse technology should always be geared towards the required performance, storage density and other aspects. In this context, a miniload system with RGB offers advantages due to its simple rack construction with low complexity. The design is less complex and the control system of an RGB is also simple, low-maintenance and can therefore have lower operating costs compared to other systems. Simple technology generally means higher availability, reliability and durability.

With moderate throughput requirements, an RGB is comparatively inexpensive to purchase and has low operating costs. Compared to shuttle systems, the RGB only needs one device that covers horizontal and vertical movements.

Another advantage of the RGB is the high load capacity, which can be up to 300 kg per container, depending on the system. Furthermore, multiple depth storage is not a problem with RGB and can significantly increase the storage density in the overall system.

How efficient is AKL with RGB?

The performance depends on factors such as the length of the aisle, the height of the shelf, the speed of the RGB and the depth of the storage. Depending on the design, a modern RGB typically achieves around 100-150 double cycles per hour. A double cycle comprises one storage and one retrieval operation. As a rough guide, a speed of 6 m/s horizontally and 3 m/s vertically can be assumed. When designing the overall system, the number of aisles is the most important factor in determining performance. If the performance requirement is too high, the number of aisles increases, which makes the miniload with RGB expensive.

Which container sizes are ipossible in a miniload with RGB?

This is where the system impresses with its high level of flexibility compared to other storage systems. It can handle plastic containers, trays, metal containers, cardboard boxes and also special containers such as polystyrene boxes or mesh boxes. As long as the load carrier is dimensionally stable and can be conveyed, there are technical solutions for handling the stored goods with an RGB or the load receptor.

In terms of size, storage systems for automated small parts warehouses are limited to the basic dimensions of 400 x 600 mm. Beyond this, we speak of large load carriers. With a view to the smallest possible load carriers, an RGB is not the ideal choice. The range in which a miniload warehouse with RGB is sensibly designed can be named from 200 x 300 mm to 600 x 400 mm.

What special requirements should be considered for an AKL with RGB?

A miniload with RGB places higher demands on structural precision, as it requires a separate device for each aisle and requires exact aisle dimensions and floor evenness. The load handling device must also be individually adapted to the containers, which is often more standardized with shuttle systems. In terms of fire protection, RGB solutions require special measures in accordance with the Industrial Building Directive (IndBauRL) and the specifications of the Association of Insurers, such as sprinkler systems in each aisle, as a failure would block the entire aisle. In addition, the mono-aisle structure requires more comprehensive maintenance and safety concepts compared to decentralized shuttle systems. These special features make RGB systems technically more demanding, but at the same time efficient with heavy loads and high storage density.

How can fire protection measures be taken into account for AKL with RGB?

The integration of fire protection into an automated small parts warehouse (AKL) with storage and retrieval machines (RGB) is a central component of planning – not only for safety reasons, but also to comply with legal regulations and insurance requirements. In the area of structural fire protection, fire compartments, fire doors and smoke and heat extraction must be taken into account. Sprinkler systems, fire alarm systems and extinguishing systems, for example with inert gas or CO2, must be taken into account in the area of system-based fire protection.