AS/RS Stacker Crane Smart Warehouse System

In an AS/RS smart warehouse, operators only need to enter inbound or outbound commands via the HMI control panel. The automated stacker crane system then performs all movement and material handling operations accurately according to system instructions.

This automated warehouse solution not only optimizes storage space but also improves operational efficiency, minimizes errors, and reduces labor costs in warehouse management.

ADVANTAGES

• Optimized storage space: Maximizes warehouse height utilization and significantly reduces the number of aisles compared to traditional solutions, resulting in increased storage capacity and more efficient space usage.
• High-density storage: With vertical lifting capability, the system can be designed up to 13 meters high (equivalent to 7 pallet levels), greatly increasing storage capacity.
• Fast inbound and outbound operations: The Selective storage method enables handling speeds of 20–25 pallets/hour, meeting the demands of continuous industrial operations.
• High accuracy: Full automation of management and operations achieves up to 98% task completion accuracy, significantly reducing errors compared to manual handling.
• Flexible operation in multiple environments: Designed to meet operating standards across various environments, including cold storage, with a temperature range from -5°C to +45°C.
• Safe and stable operation: Equipped with sensors, safety fences, and intelligent protection systems to minimize workplace accident risks.
• Scalability: Modular design allows easy system expansion as business needs grow, without interrupting current operations.

SYSTEM STRUCTURE

Storage Rack & Frame System

The metal rack frame system forms the main structural backbone of the warehouse, responsible for supporting all stored goods.
The structure is typically made from high-strength steel with excellent load-bearing and wear resistance. In special environments, galvanized steel or powder-coated steel can be selected.
Rails are installed between rack aisles to guide the movement of the automated stacker crane for storage and retrieval operations.

SAFETY SYSTEMS

Collision prevention sensors

• Function: Prevent collisions between the stacker crane and obstacles or goods
• Type: Infrared sensors or ultrasonic sensors

Emergency stop system

• Function: Immediately stop the system to ensure safety during abnormal conditions
• Type: Infrared sensors or ultrasonic sensors

Temperature monitoring sensors

• Function: Monitor environmental conditions, such as temperatures exceeding 30°C
• Type: Temperature and humidity sensors

AUTOMATED PALLET STACKER CRANE

The automated pallet stacker crane is specifically designed for pallet storage in smart warehouses and AS/RS systems. With a robust structure, it ensures high safety, stability, and reliability throughout operation.

The control system uses a vector variable frequency drive (VFD) combined with encoders to achieve high positioning accuracy. Integration of an S-curve motion control module enables smooth, fast, and precise crane movements.

To ensure continuous and safe operation, the system is fully equipped with mechanical and electrical protection solutions that meet the stringent requirements of modern industrial environments.

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Miniload Stacker 

The Miniload stacker crane is an optimal solution for AS/RS smart warehouses, designed to handle storage units smaller than pallets with high speed, light loads, and exceptional flexibility.

The system can be configured as single-column or double-column, depending on load capacity and warehouse height, and supports multiple load-handling devices to accommodate various types of goods.

• Single-column Miniload stackers are ideal for small parts, components, and detailed items.
• Double-column Miniload stackers are better suited for bulky goods such as pallets, bins, trays, boxes, and cartons.

A key advantage of Miniload stackers is their ability to handle a wide variety of goods, regardless of shape or surface, maximizing storage efficiency and automation.

Miniload Stacker Technical Specifications

APPLICATIONS

The AS/RS (Automated Storage and Retrieval System) is widely applied across modern industries thanks to its ability to fully automate storage processes, optimize space, and enhance operational efficiency.

From large manufacturing plants to distribution centers, AS/RS is an ideal solution for businesses handling large volumes of goods, diverse SKUs, and requiring high speed, accuracy, and safety.

Typical application industries include:

• Automotive & motorcycle: Storage of components, spare parts, and finished pallets
• Electronics & semiconductors: Storage of small, high-value materials
• Food & pharmaceuticals: Temperature-controlled storage with FIFO management
• E-commerce & logistics: Faster order fulfillment and reduced labor costs

Whether for -30°C cold storage, high-bay warehouses, or space-limited facilities, AS/RS systems can be fully customized to meet all modern storage requirements.