The upcoming IntraLogisteX exhibition being run alongside the Robotics & Automation exhibition, is indicative of the ever-increasing role automation plays in material handling. Exhibitor PLUS Automation, who will be on stand 1335, shared this application on vertical storage systems by their manufacturing partner ReeR Safety.
In the fast-paced world of automated warehousing, maximising throughput while ensuring operator safety is a constant balancing act. When System Logistics, a global leader in automated storage solutions, developed its next-generation “Modula Lift” vertical shelving system, it turned to advanced optoelectronic technology to bridge the gap between high-speed performance and stringent safety standards.
The Modula Lift is an advanced vertical storage solution designed to optimise floor space and improve picking accuracy. At its core, an automatic elevator retrieves and stores metal drawers within a high-density shelving unit. To ensure the machine operates at peak efficiency, the system requires a sophisticated hardware and software interface that manages both machine measurement and safety functions simultaneously.
The Challenge: Seamless Integration
System Logistics approached the project with two primary objectives. Firstly, they required a safety solution with a significantly reduced cross-section. Traditional, bulky safety curtains would interfere with the machine’s streamlined structure, so the goal was to find a low-profile solution that could be integrated directly into the protection shields.
Secondly, the “external bay” design of the Modula Lift required comprehensive protection for the dangerous area. This necessitated both vertical and horizontal monitoring to prevent accidental access while the elevator and drawers were in motion.
Precision Measurement at High Speed
Beyond safety, the functional requirements for height measurement were rigorous. To maximise storage density, the system must precisely measure the height of objects within each drawer to determine the best storage location.
System Logistics identified four critical criteria for this measurement:
- Homogeneity: Consistent readings across the entire width of the drawer (left, right, and centre).
- Sensitivity: The ability to detect objects as small as 4mm.
- Speed: Detection must be accurate even when the drawer is in rapid motion, with speeds reaching up to 575 mm/s.
- Reliability: Immunity to optical reflections from the metal drawers and serial communication for easy data integration.
The Solution: A Dual-Purpose Approach
To meet these demanding specifications, a combination of ReeR EOS2 safety light curtains and MICRON measurement curtains was deployed.
Safety without Compromise
The ReeR EOS2 model was selected for its compact form factor, allowing it to be housed within the machine’s frame without compromising structural integrity. By utilising a Master-Slave configuration, the engineers achieved an “L-shaped” detection zone, providing the required horizontal and vertical protection. With a 30mm resolution and customisable heights to suit different machine sizes, the EOS2 ensures the hazardous zone remains inaccessible during operation.
Advanced Measurement Dynamics
For the measurement task, the MICRON MI 752 D B was integrated inside the storage unit. Boasting a 25mm resolution, the curtain provides the necessary homogeneous reading across the drawer’s span.
One of the standout features of the MICRON system is its diaphragmed optics. This technology allows the system to detect 4mm objects even at the Modula Lift’s peak acceleration and transit speeds (ranging from 440 mm/s to 575 mm/s). Furthermore, the reduced divergence of the optics a feature typically reserved for high-end safety curtains—provides exceptional immunity to reflections from the metallic surfaces of the drawers, eliminating false readings.
Conclusion
By integrating these advanced sensing solutions, System Logistics has ensured that the Modula Lift is not only one of the safest vertical lift modules on the market but also one of the most precise. The use of customisable serial communication protocols allowed the sensors to talk directly to the machine’s internal software, creating a seamless, high-speed automated environment that meets the rigorous demands of modern logistics.
The result is a reliable, high-performance system that proves that in the world of industrial automation, safety and productivity don’t have to be mutually exclusive.
Read other recent news: https://industrial-compliance.co.uk/category/news/
