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2013 MHI? Copyright claimed as to audiovisual works of seminar sessions and sound
recordings of seminar sessions. All rights reserved.
Sponsored by: Presented by:
Ralph Mills
Director Integrated Systems
Latest Automated Storage & Retrieval
System (AS/RS)Technology �CTwo Cranes,
One Aisle

Two Cranes / One Aisle
Dual Mini Load AS/RS
Dual Mini Load

Topics Covered
Mini Load �C What is the Load?
Typical Mini Load Automation
�C Crane in Aisle
�C Shuttle
�C Dual
Dual Mini Load
Sequencing
Kitting
Summary

Load
Cartons
Can store end
down aisle Can store side
down aisle
Can even work
with good cartons

Loads
Totes
Corrugated
Plastic
Tote
ESD
Plastic
Tote
Corrugated
Carton
used as
Tote

Crane in Aisle Mini Load
Storage Retrieval Machine (SRM) Single Aisle ASRS

Crane in Aisle
Mini Load
? Load weight capacity:
220 lbs.
? Machine height:
33 ft.
? Horizontal speed:
650 ft./min.
? Vertical speed:
260 / 330 ft./min. Full / MT
? 2 extractors per machine
? Side belt extractors
? Proven Technology
1000s of installations
Mini-Load AS/RS

Shuttle Type Mini Load

Shuttle Type Mini Load
Lift
Conveyor
P&D
Conveyor
Tote
Shuttle

Dual Mini Load
Crane-In-Aisle Mini
Load & Shuttle
Carousels
Rate vs. Storage
Locations
Totes
per
Hour
Manual

Dual Mini Load

What��s different about
Dual Mini Loads

Typical Dual Mini Load

Dual Mini Load Video

Specifications
Tabel Duosys
Model Duosys
SRM 2 SR/Level
Design Load Weight 66 lbs maximum including tote
Load extractor type Underbelt
Horizontal Speed 984 ft/min, inverter drive
Vertical Speed 131 ft/min inverter drive
Load transfer time P&D with synchronous transfer = 2 seconds; rack =
3 seconds
Machine Frame Aluminum, extruded and fabricated
Controls Design SRC-VI controller
Handy Terminal portable interface terminal
SRM operation box
SRC operation box
Position learning
Communication with SRM �C IR Optical Data
Transceiver
Rail Stop Hydraulic stoppers, both ends of aisle
28 �C 104F, 10-90% RH, non-condensing
Standard Daifuku Paint on non-aluminum parts
Load width protrusion sensor
Power Requirement 208 VAC 60 Hz 3 Phase
Load Envelope- Max 23.6��L x 24��W x 24�� H
Environment
? 300 m/min Horizontal speed
? 3.5 m/s2 Horizontal acceleration
? 80 m/min Vertical speed
? 3 .5 m/s2 Vertical acceleration
? 2 s Average transfer time
? 30 kg 66 lbs Maximum load weight

220C/H
0.1G
200m/min
Single Motor
Drive
330C/H
0.3G
200m/min
Twin Motor
Drive
2002
High
Acceleration
x 1.5
500C/H
0.5G
500m/min
Synchronous
Motor control
2 wheels
& 4 motors
High
Traction
Drive
Anti Mast Sway
Fastest ML
In the world
2004
x 1.5
800C/H
0.6G
400m/min
Lightweight
��CFRP Mast��
2 SRM per Aisle
Single CPU-
Off-Board Ctrl
Responsive
System
2006
x 1.6
Heritage of High Speed
Mini load
Throughput
Travel Speed
Acceleration
Concept
Technology
High Speed
2000
Base Condition��Travel Stroke 20m, Clear Height 6m
Throughput above is based on best case scenario
2200C/H
0.4G
350m/min
Multi Layer -
Double Decker
2 SRM per Aisle
& By-Pass Ctrl
Offset Frame
High System
Throughput
2008
x 2.5
Year

Features of Dual Mini Load
Non-Stop System (Redundancy)
? When one crane stops
? Second crane continues working
? Accessing all locations
Ecology System
? Lightweight design saves electricity
? Regenerative braking creates electrical power that is
sent to the other crane through a regenerative converter
? One SRMs is inactive during low utilization
High Maintainability
? One crane can be in maintained while the other is
working
? Maintenance can be systematically implemented by
controlling the numbers of active SRMs.
High Throughput
? Two cranes works in the same aisle
? Cranes pass each other without interference

Patent pending
S yn c h r o n o u s Co n t r o l
2 cranes works in one aisle moving past each other without interference
I can access any carton
in both left and right
shelves across entire
aisle.
I can by-pass crane #2
to go to the station
because #2 is still in
transfer process.
1
2
Crane #1 working zone
Crane #2 working zone

Patent pending
S imul t an eo us Tr an s f er
Non-stop Transfer
No idle time
2 SRM do unloading
and loading at the
same time!
Unloading and loading transfer at the conveyor
1
2
*1 : Not applicable to fork extractor alone.

Patent pending
e.g. load size error
Crane 1 works, with load error on crane 2
Carton accessible by crane #1
1 2
Carton not accessible by crane #1
H ig h Avail abil it y
Non-Stop System

Non-Stop System
? One crane encounters a bad case
? Other crane can by-pass and continues to operate
Error
occur
��܇݆
A
A

Patent pending
H igh Main t ain abil it y
1
2
DUOSYS remains in operation while maintenance is performed on
one SRM. Maintenance can be systematically implemented by
controlling the numbers of operations of individual SRM.
I keep working
alone until my
partner is back from
maintenance
Maintenance area
Non-Stop System
System

Non-Stop System
��܇݆
A
Movable Fence
Safety
Interlock Plug
? One crane can be maintained
? While other crane continues to operate

Ecology System
Effects of light weight design and regenerative converter
Conventional Miniload
? Model R-P1
? x 3 aisle 3SRM
? Without regenerative
converter
15.4 [kWh]
Horizontal: 200m/min 0.1G
Vertical: 40m/min 0.15G
8.1 [kWh]
Energy
Saving
48%
Example 600 cases/hr
Horizontal: 350m/min 0.4G
Vertical: 40m/min 0.3G
Model Dual Mini Load
? x 1 aisle 2SRM
? With regenerative converter
Weight Savings 30%
Accel adder 20%
Regen Savings 38%

Collision Proof Technology
Extractor
SRM-1
Laser Scale
On-board
Speed Command
Servo
Servo
MO
MO
Servo
Servo
MO
MO
Servo
Servo
MO
MO
Servo
Servo
MO
MO
PLG PLG PLG PLG PLG PLG
PLG
PLG
Off-Board
Carriage
C-Language
Controller
Motion
Controller
Ethernet
Off-Board Controller
Position Feedback
SRM-2
On-Board
Lower
Frame Carriage
Lower
Frame
Vertical Horizontal Horizontal Vertical Extractor
High Speed Motion Control
Single CPU controls two cranes.
Dual Feed Back Control
Laser distance sensor
Motor axis encoder [PLG]
Accurate position control

Verification of Collision
Proof
Simulation Test
? 10 years of duty cycles on software.
? Simulation software incorporating all
logic proved no collision or deadlock.
Real Machine Test
? 700,000 cycles tested by prototype
? Installed 3 test sites
? Many cranes installed
? Over 100,000,000 cycles, no collisions Screen Shot of Simulator

Benefits
? Speed
? Rack Side Delivery
? Multiple Level Output
for Sorting
? Flexibility in Load Size
? Simultaneous Transfer
? Reliable
? Save
? Proven Technology

Case Study
Order Sequencing

Order Sequencing
System

Sequencing Simulation
Video

32
3D Sorter for Shipping
3D Buffer and Sorting
by Duo Mini Load
Conventional
��Sorter + Chute�� solution
Dual Mini Load changes the
conventional ��Sorter + Chute
buffering�� solution to new ��3D
Buffering & Sorting�� solution,
allowing your shipment to be
prepared in exact sequence in a
shorter period in less space.
horizontal space is cut by 50%
Dual Mini Load
Conventional system

Distributed Sequencing
Add graphic

Case Study
Rack Side Picking

Overall System

ML feeds Dual Mini Load

Plan of Dual Mini Load

Rack Side Picking
SPB Pick Station
SA Pick Station

Work Flow
Barcode
Reader
Pick To
Carton
Pick From
Tote

Work Flow

Dual Mini Load
Summary
? Dual Mini Load is a NEW Application
?AS/RS as ��Vertical Sorter��
?Not a New Technology
? Dual Mini Load was developed based on Field
Proven AS/RS Components
? High Speed Evolution
? Intensively pursuing High Speed, High
Throughput SR Machines since 2000
? Dual Mini Load Speed Evolution is Field
Proven
?Added features
? Ecology, Redundancy, and Maintainability
?Dual Mini Load is one part of Automated Storage
? Can be combined in system depending on application
?Collision Proof Software is proven with over 100,000,000 cycles
? Dual Mini Load was developed aiming at high speed sequencing and picking
systems

Speaker: Ralph Mills
rmills@daifukuwebb.com
Home Page: www.daifukuwebb.com
Visit ProMat 2013 Booth 1512
For More Information:

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639.pdf

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