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Abalioglu - Kullanım - Klavuzu - ING PDF
Abalioglu - Kullanım - Klavuzu - ING PDF
Table of Contents
1 INTRODUCTION ................................................................................................................ 12
1.1 Purpose of the instructions ............................................................................................... 12
1.2 Safety symbols and warnings ............................................................................................ 12
1.3 Applicable Health and Safety Legislation ........................................................................... 14
1.3.1 Basic Health and Safety Procedures .................................................................................. 15
1.3.2 After Servicing .................................................................................................................. 18
1.3.3 Fire Precautions ................................................................................................................ 18
1.3.4 Maintenance .................................................................................................................... 18
1.4 Project Directory ............................................................................................................... 20
2 INSTALLATION DESCRIPTION ............................................................................................ 21
2.1 Basis of design .................................................................................................................. 21
2.2 Purpose of the Installation ................................................................................................ 21
2.3 Applicable Standards ........................................................................................................ 21
2.4 Mechanical equipment ..................................................................................................... 21
2.4.1 Conveyor system .............................................................................................................. 21
2.4.2 Shuttle C501 ..................................................................................................................... 42
2.4.3 Shuttle C401 ..................................................................................................................... 49
2.4.4 Crane ................................................................................................................................ 56
2.5 Electrical equipment ......................................................................................................... 65
2.5.1 Description of the electrical system .................................................................................. 65
2.5.2 Distribution power supply +SB1 ........................................................................................ 65
2.5.3 Conveyor system power supply......................................................................................... 65
2.5.4 Crane and shuttle power supply........................................................................................ 66
2.5.5 Main cabinets ................................................................................................................... 66
2.5.6 Main power consumers .................................................................................................... 68
2.5.7 Control circuits.................................................................................................................. 71
2.5.8 Sensors ............................................................................................................................. 71
2.5.9 Communication ................................................................................................................ 73
3 SAFETY ............................................................................................................................. 74
3.1 General measures ............................................................................................................. 74
3.1.1 Uncontrolled cutout of electrical energy ........................................................................... 74
3.1.2 Vehicles stability ............................................................................................................... 74
GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 2/251
1 INTRODUCTION
Table of Figures
Figure 2.1 Main parts of the chain conveyor................................................................................................. 22
Figure 2.2 Driving Station ............................................................................................................................. 23
Figure 2.3 Turning Station .............................................................................................................................23
Figure 2.4 Chain ............................................................................................................................................23
Figure 2.5 Main parts of the roller conveyor .................................................................................................25
Figure 2.6 Driving Station ..............................................................................................................................26
Figure 2.7 Main parts of the roller conveyor .................................................................................................28
Figure 2.8 Driving Station ..............................................................................................................................29
Figure 2.9 Eccentric Lifting Table ...................................................................................................................31
Figure 2.10 Main parts of the eccentric lifting table ......................................................................................32
Figure 2.11 Main parts of the eccentric lifting table ......................................................................................32
Figure 2.12 Lifting device ..............................................................................................................................33
Figure 2.13 Stopper ......................................................................................................................................35
Figure 2.14 Main parts of the stopper ...........................................................................................................36
Figure 2.15 Contour check ............................................................................................................................38
Figure 2.16 Main parts of the weight control ................................................................................................39
Figure 2.17 Main parts of the control of dimensions .....................................................................................40
Figure 2.18 Pallet base control ......................................................................................................................41
Figure 2.19 Main parts of the pallet base control ..........................................................................................41
Figure 2.20 Shuttle with two roller conveyors ...............................................................................................42
Figure 2.21 Main parts of the shuttle C501....................................................................................................43
Figure 2.22 Shuttle frame .............................................................................................................................44
Figure 2.23 Driving set .................................................................................................................................44
Figure 2.24 Driving unit.................................................................................................................................45
Figure 2.25 Hydraulical bumper ....................................................................................................................45
Figure 2.26 Roller conveyor on tilting mechanismus......................................................................................46
List of Tables
Table 1.1 Notes and warnings ...................................................................................................................... 13
Table 1.2 Considered regulations and rules Standards.................................................................................. 14
Table 1.3 Contacts table ...............................................................................................................................20
Table 2.1 Main parts of the chain conveyor ...................................................................................................22
Table 2.2 Technical data of the chain conveyor .............................................................................................24
Table 2.3 Technical data of the driving motorgearbox ...................................................................................24
Table 2.4 Main parts of the roller conveyor ...................................................................................................25
Table 2.5 Technical data of the roller conveyor .............................................................................................27
Table 2.6 Technical data of the driving motorgearbox ...................................................................................27
Table 2.7 Main parts of the roller conveyor ...................................................................................................28
Table 2.8 Technical data of the roller conveyor .............................................................................................30
Table 2.9 Technical data of the driving motorgearbox ...................................................................................30
Table 2.10 Technical data of the eccentric lifting table ..................................................................................34
Table 2.11 Technical data of the driving motorgearbox .................................................................................34
Table 2.12 Main parts of the stopper ............................................................................................................36
Table 2.13 Technical data of the stopper.......................................................................................................37
Table 2.14 Technical data of the driving motorgearbox .................................................................................37
Table 2.15 Main parts of the weight control ..................................................................................................39
Table 2.16 Main parts of the control of dimensions.......................................................................................40
Table 2.17 Main parts of the pallet base control ...........................................................................................41
Table 2.18 Main parts of the shuttle C501 .....................................................................................................43
Table 2.19 Technical data of the shuttle ........................................................................................................47
Table 2.20 Technical data of the driving motorgearboxes .............................................................................48
Table 2.21 main parts of the shuttle C401 .....................................................................................................50
Table 2.22 Technical data of the shuttle ........................................................................................................54
Table 2.23 Technical data of the driving motorgearboxes .............................................................................55
Table 2.24 Crane main groups .......................................................................................................................56
Table 2.25 Crane technical data ....................................................................................................................62
Table 5.1 Delivery and dispatch conveyors ..................................................................................................103
Table 5.2 Permanently blocked rack locations .............................................................................................104
Table 5.3 Segments.....................................................................................................................................110
Table 5.4 Buttons and their actions .............................................................................................................126
Table 5.5 Buttons and their actions .............................................................................................................144
Table 5.6 Buttons and their actions .............................................................................................................161
Table 7.1 Maintanance parts of the driving station ....................................................................................196
Table 7.2 Maintanance parts of the chain conveyor ....................................................................................197
Table 7.3 Lubrication plan of the chain conveyor ........................................................................................198
Table 7.4 Maintanance parts of the roller conveyor ....................................................................................200
Table 7.5 Lubrication parts of the roller conveyor .......................................................................................201
Table 7.6 Maintanance parts of the roller conveyor ....................................................................................203
Table 7.7 Lubrication parts of the roller conveyor .......................................................................................204
Table 7.8 Maintanance parts of the lifting device ........................................................................................207
Table 7.9 Lubrication parts of the lifting device ...........................................................................................207
Table 7.10 Maintanance parts of the stopper ..............................................................................................210
Table 7.11 Lubrication parts of the stopper .................................................................................................211
Table 7.12 Maintanance parts of the weight control ...................................................................................212
GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 10/251
1 INTRODUCTION
1 INTRODUCTION
Instructions clearly define the purpose of the use of the system and contain all data necessary for assuring safe and
correct use of the system.
Information contained herein is intended to professionally qualified persons. Person is professionally qualified if he or
she possesses necessary knowledge (professional knowledge, knowledge about safety and health when using the
equipment, etc.) and competences.
Permanent following and compliance with instructions, norms and standards given by the manufacturer is a guarantee
(warranty) for the safety of personnel and the system, its economical use and long life span.
This manual is to be used by operators in charge of managing the system during its working life.
It is important to keep the manual in a readily accessible place, near the machine and well-known to all the operators in
charge of operating and maintaining the system. The operators and the maintenance staff must be able to quickly find
and consult the manuals and the annexes in any situation.
It must be kept intact. Immediately request a copy if the manual gets lost or damaged;
It must stay with the system until its destruction (also in case of transportation, sale, lease, etc.);
It must be kept updated and include any changes introduced.
Any personnel carrying out work on the system should have suitable levels of training, qualification and competence.
This manual is written with this in mind. If any works are to be carried out on the system, then this manual should be
referred to before work commences. Should the particular issue not be covered by this manual then please refer to the
Installing Contractor, before undertaking such works.
The present manual contains the necessary information for installation, operation, maintenance and cleaning of the
system in its entirety. These instructions are divided in chapters to make reading easier; in order to find a particular
chapter more quickly, use of table of contents is recommended!
Notes or warnings are written in bold and marked with symbols as presented in Error! Reference source not found..
DANGER Compliance with the instructions is obligatory. Failure to comply with the instructions may lead
to injuries or death!
WARNING Warning about a situation, which may arise in life span of the product, or the system and which
can represent potential hazard for personal injury or property damage, environment pollution
and economic losses.
ATTENTION Warning which must be considered, to avoid serious damages on the machine and personnel.
NOTE:
Some information and illustrations in these instructions can be different from the ones on your machine. This sign
stands for specific information relating exclusively to your machine.
During the design and safety management on the transport vehicle the following standards, regulations and rules given
in Table 1.2 have been considered.
Standard Description
Ur. l. RS No. 75/2008 Machinery Safety Rules
SIST EN ISO 12100-1 Machinery safety Basic notions, general principles of planning Part 1
Basic terminology, methodology
SIST EN ISO 12100-2 Machinery safety Basic notions, general principles of planning Part 2
Technical principles
SIST EN ISO 13857 Machine safety Safety distances preventing reach of dangerous areas with upper and
lower limbs
SIST EN 349 Machinery safety Least distances preventing contusions on human body parts
SIST EN ISO 13850 Machinery safety Emergency stop Principles of planning
SIST HD 516 S2 Directions for use of low voltage adjusted cables
SIST EN 953 Machinery safety Safety devices General directions for planning and construction of
fixed and movable safety devices
SIST EN 954-1 Machinery safety Parts of command systems
SIST EN 981 Machinery safety Systems of visible and audible hazards or notice signals
SIST EN 1037 Machinery safety prevention of the hazardous switch-on
SIST EN 14121-1 Machinery safety Risk assessment Principles (methodology of evaluation, list of
dangers)
SIST EN 50085-1 Systems of cable troughs and system of cable tubes for el. installations
SIST EN 50086-1 Systems of channels for el. installations Part 1
SIST EN 60204-1 Machinery safety Electrical machine equipment Part 1: General requirements
SIST EN 60204-32 Machinery safety - Electrical machine equipment Part 32: Special requirements for
lifting machines
SIST-EN-528-2008 Rail dependent storage and retrieval equipment Safety requirements
situations of danger that might arise during use and maintenance of the system;
protections, guards and safety devices and their correct use;
residual risks and behaviors (general and specific precautions to eliminate or limit them).
The instructions and safety warnings referred to in this manual take into account
1.3.1.1 General
Before commencing any task, give careful consideration to
The employer, the manager, and the person in charge of safety must, when assigning duties to workers:
take into account their capability and the condition of their health and safety;
supply the proper individual safety devices;
require each operator to observe the corporate regulations and instructions regarding safety and the use of
the collective or individual protection devices available for them.
accident risks,
operator safety devices,
risks produced by noise emissions and
general accident-prevention measures contemplated by European directives and by the legislation of the
country where the system is to be installed.
analyze all dangers of the system by assessing the probability of risk based on the functioning methods and the
installation location;
restrict the passage of forklifts;
sensitize and train staff responsible for operations on the work posts and the staff responsible for operating
the system;
apply visual safety signs.
observe the rules and instructions provided by the employer, the manager and the person in charge regarding
collective or individual protection;
correctly use the machinery, equipment, tools, dangerous substances and preparations, means of transport
and handling and any other working equipment in addition to the safety devices;
correctly use the protection devices provided;
immediately inform the employer, manager or person in charge of any deficiency in the safety devices.
All work proposed should only be considered if the plant or the consequences of the operator working on the plant are
carried out in circumstances that are made safe.
An interlock system (similar to Permit-to-Work) should be employed to safeguard the operator and/or any person who
may be affected by the actions of the operator.
Should an accident occur follow the procedures according to the High-bay rack warehouse Abalioglu rules or by the
Local Authority.
Control panel cubicle(s) or distribution boards open for prolonged periods of maintenance must be isolated with
barriers, and clearly visible HAZARD, WARNING, CAUTION or DANGER notices displayed: this a mandatory requirement
irrespective of whether the plant is attended or not.
Preserve life This includes the life of the casualty, bystander and rescuer;
Protect the casualty from further harm Ensure the scene is safe;
Provide pain relief This could include the use of ice packs or simply applying a sling;
Prevent the injury or illness from becoming worse Ensure the treatment you provide does not make the
condition worse;
Provide reassurance.
It is important to understand that first aid has its limitations and does not take the place of professional medical
treatment.
If the assistance of medical or nursing personnel will be required immediately send for a doctor or nurse (where they
are employed at the workplace) or an ambulance. When an ambulance is called, arrangements should be made to
direct it to the scene immediately.
For detailed guidance on first aid procedures refer to High-bay rack warehouse Abalioglu or the Local Authority
guidelines for safe working practices.
INFORMATION The operators and maintenance should NOT consider the following advice to be the SOLE
reference for safety purposes; they are represented merely as reminders of the most basic of
safety considerations.
The operators shall always be aware of the following when accessing the different areas:
Use individual protection means suitable to the risk they have to face. Operators should wear work clothes
(with tight sleeves) and, if necessary, personal protection equipment (gloves, goggles, masks, safety anti-slip
footwear, etc.) in compliance with the legislation and regulations in force in the respective country;
Do not use the system improperly, that is, do not use the system in any manner other than that indicated in
the manual;
When the sytem is operating, do not work near the system wearing chains, bracelets, ties or any other piece of
clothing that might get entangled with the mechanisms. Tie up long hair;
Do not seize with your hands to dangerous areas of movement (rotational or moving);
Make sure that there are no persons in dangerous areas when the machine is started;
During manual operations pay utmost attention to prevent damage to persons or things;
Make sure the floor is regularly cleaned, entering material must be in flawless condition;
Always make sure that safety devices and other means of protection are properly installed.
ATTENTION Each operator must attend to his/her own safety and health and that of others present in
the working area who might suffer the effects of his/her actions or operations, in
accordance with training and the instructions and resources supplied by the employer!
WARNING The vehicles in the plant operates automatically. You cannot predict when and where a vehicle
will move.
In the system there are three cranes and two shuttles. In order to prevent injuries of the operators when accessing, the
system of keys should be used. The system of keys consists of a key-lock outside the crane or shuttle area and one key-
lock on each crane and shuttle. Only one key should be used for manipulation of key-locks. The operator can only
approach a vehicle when he possesses the key. In remote operation (automatic mode) the key is in the key-lock outside
the transport vehicles area. To stop the vehicles movement, the operator has to take the key from the key-lock and
wait for appropriate signal. Only when the vehicles stop, he can access the vehicles area. For local operation of a
vehicle, the operator has to put the key to the key-lock of the selected vehicle. The procedure is further detailed in later
sections.
For maintenance works it is recommended that the Permit-to-Work scheme is introduced by the management. If
correctly operated, the benefits of a Permit-to-Work system can contribute significantly to a safe working environment
and an orderly working regime. The Permit Officer shall only authorize commencement of any maintenance or repair
task upon receipt of the appropriate application for a Permit-to-Work. The Permit Officer is to check and assume
responsibility for placement of all "DANGER", "CAUTION" and/or "LIVE" notices prior to issue of the Permit. When the
work is complete or interrupted the operative shall sign the Permit, acknowledging the work to be complete or
interrupted. Only when all Permits pertaining to the plant/equipment on which work has been carried out are returned
to the Permit Officer will the plant/equipment should be returned to normal operation.
The following regular and routine checks should be carried out to ensure that they are always capable of functioning
correctly. Report any defects or issues to the System Management.
Ensure that all fire-fighting equipment Is fully tested and operational at all times.
Ensure that fire-fighting equipment is suitable for use on electrical systems.
Ensure emergency lock-stop buttons are clearly labelled;
Ensure all doors to the system are kept shut;
Ensure hand fire appliances are kept in their proper locations and regularly checked by the Civil Defense or
manufacturers;
Ensure the correct extinguishers are available for dealing with the likely types of fires in the areas covered by
them. (For any information and advice in this respect consult the local Civil Defense).
In the vicinity of the operating area a fire extinguishing system is recommended. For electrical devices use Dry Powder
(class A, B, C) or CO2 Gas (A limited, B).
If you discover a fire, you must get everyone out as quickly as possible and call the Civil Defense. However, you may
discover a fire in its very early stages and think that you can deal with it yourself. The first thing that you should
remember is that fire spreads very quickly. Even a small contained fire can quickly spread, producing smoke and fumes
which can kill in seconds. If you are in any doubt do not tackle the fire, no matter how small. You can put yourself at risk
by fighting the fire.
1.3.4 Maintenance
All maintenance procedures are described in these instructions. Do not perform maintenance or other operations not
provided in these instructions.
Consistent compliance with these instructions is the condition for safe use of the machine and its long life span.
INFORMATION Only professionally qualified and authorized personnel may use and maintain the machine
after thorough reading and understanding of these instructions!
Notes for maintenance in addition to the notes for operators given in section Basic Safety Guide:
Before working with any system that can cause potential harm always ensure that you are aware of local
emergency procedures and the locations of emergency equipment.
Ensure that all the require documentation has been submitted and approved before commencing works.
It is the responsibility of each individual to ensure that, via the application of plain "common sense" and the
mandatory safety regulations, each task is carried out safely.
Always allow the system to roll to a stop naturally. Never attempt to shorten the time by holding system parts.
Carry out maintenance operations with the system switched-off.
Always assume every circuit is 'live' until it has been checked with a voltmeter, or similar approved means:
check your instruments with a known 'live' source before using them for testing.
Never touch two sides of a circuit simultaneously, whether it is alive or dead.
Whenever work is to be carried out on a vehicle or equipment all electrical isolators should be locked off and
all fuses covering the item should be removed as an added safeguard. Indicate at main panel that work is being
carried out on particular plant. Lock off electrical supplies where possible and retain the key(s).
Turn off the master switch and lock it with a padlock before operating on the electrical board, the junction
box, cables and any other electrical component of the system. The fact of being impossible for unauthorized
persons to remove the lock will allow carrying out the relevant operations in safety.
Do not use metal rules or measuring tapes when working on or near live equipment.
Always use tools with hand grips adequately insulated against the voltage of the circuit being worked on.
Do not lubricate when the moving parts are in motion.
Always remove guards, access panels and other safety devices immediately the work in hand is completed.
When maintenance or repair work is either interrupted or complete then it is the responsibility of the engineer
or individual in charge to ensure that the plant is left in a safe condition.
2 INSTALLATION DESCRIPTION
Chain conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the conveyor. Chain
conveyor can work as independent unit or can be built in another working unit.
Pos. Name
1 Longitudinal beam
2 Drive station
3 Turning station
4 Chain
5 Chain guiding
1 3 4 5 2
Chain conveyors components are screwed together. Longitudinal beam consists steel tube and two turning
station screwed on it. Both longitudinal beams are connected with distance beams.
On the bottom side, there is drive station mounted. Both chains are guided with standard chain guiding.
Longitudinal beam is made of rectangural tube. Chain guidings are conected to them.
Driving station is assembled of driving shaft, housing units with bearings, driving and turning sprockets and
motorgearbox. Driving sprockets and gearbox are connected to the shaft with clamping devices.
Chain runs over turning sprockets of the driving station and both turning stations and over the tensioning
sprocket of the driving station which allowes us to make proper tension of the chain.
Chain is supported with standard plastic chain guiding
Driven roller conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the roller conveyor.
Roller convyor can work as independent unit or can be built in another working unit.
Pos. Name
1 Longitudinal beam
2 Cover
3 Driving station
4 Drive
5 Roller
6 Driving belt
7 Driven belt
4 2 3 1
4 3 6 7
Roller conveyors components are screwed together. Rollers are mounted between 2 longitudinal beams.
Longitudinal beams are protected with covers. Driving station is mounted on one of the longitudinal beams.
Timing belts are used for movement transfer. Driving timing belts drives two nearest rollers, all other rollers
are conected with another driven timing belts.
Longitudinal beam is made of C profile with holes rollers which are 200mm apart. Rollers are conected to the
beam with screws.
Rollers are standard purchased elements. Diameter of the rollers is 88,9mm. There are 2 sealed bearings inside
of the roller and double timing sprocket on one end of the roller.
Driving station is assembly with motorgearbox, driving timing bar sprocket which is connected with Taper Lock
bush, and driving timing belt. Tension in the driving timing belt can be adjusted by vertical adjustment of the
Motorgearbox.
Capacity 2x10 kN
Dimensions
Width 975 mm
Speed:
Other data:
Control voltage 24 V DC
Driven roller conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the roller conveyor.
Roller conveyor can work as independent unit or can be built in another working unit.
Pos. Name
1 Longitudinal beam
2 Cover
3 Drive station
4 Drive motorgearbox
5 Roller
6 Driving belt
7 Driven belt
5 2 1 7 4 6 3
Roller conveyors components are screwed together. Rollers are mounted between 2 longitudinal beams.
Longitudinal beams are protected with covers. Driving station is mounted on one of the longitudinal beams.
Timing belts are used for movement transfer. Driving timing belts drives two nearest rollers, all other rollers
are conected with another driven timing belts.
Longitudinal beam is made of C profile with holes rollers which are 200mm apart. Rollers are conected to the
beam with screws.
Rollers are standard purchased elements. Diameter of the rollers is 88,9mm. There are 2 sealed bearings inside
of the roller and double timing sprocket on one end of the roller.
Driving station is assembly with motorgearbox, driving timing bar sprocket which is connected with Taper Lock
bush, and driving timing belt. Tension in the driving timing belt can be adjusted by vertical adjustment of the
Motorgearbox.
Capacity 2x10 kN
Dimensions
Width 975 mm
Speed:
Other data:
Control voltage: 24 V DC
Eccentric lifting table which has a roller conveyor on board is situaded in the middle of chain conveyor. Eccentic lifting
table is used for lifting and lowering the roller conveyor. In upper position, the roller conveyor is abowe the chain
conveyor and in bottom position ther is opposite situation. That enables to take over the pallet from roller conveyor to
the chain conveyor and opposite. Movement of the pallet on the roller conveyor an on the chain conveyor is
perpndicular.
Pos. Name
1 Bottom frame
2 Upper frame
3 Lifting device
Bottom frame is welded part made of rectangural tubs and plates.It has 4 leveling which enables us to level the
device.
Upper frame is welded part made of rectangural tubs and plates. It is adjusted for fixing the roller conveyor.
Lifting device. Lifting is done with eccentric. Device consist motorgearbox, driving shaft and two shafts with
eccentric arms, driving sprocket and chain, housing units with bearings and holders fort he upper frame.
With turning of the eccentric arms for 90 degrees, lifting or lowering is enabled.
Capacity 10 kN
Dimensions
Length 1040 mm
Width 870 mm
Lifting height 40 mm
Speed:
Other data:
Control voltage 24 V DC
2.4.1.5 Stopper
Stopper is used for stopping and alignement of the pallets at desired situation.
Movable part of stopper is lifting and lowering and stops the pallet when it is in upper position or pallet pass over
when it is in bottom position.
Lifting movement is inclined so that it does not scratch the pallet during movement.
Pos. Name
1 Bottom frame
2 Guiding frame
3 Movable part
4 Motorgearbox
Bottom frame is anchored to the ground. Position of the bottom frame and those complete stopper can be
adjusted.
Guiding frame is atatched to the bottom frame. It consists linear guiding profiles..
Movable part. Is stopping the pallet. The shape is different if it stops the pallets comming paralel or
perpendicural on the roller conveyor.
Capacity 10 kN
Dimensions
Lifting height 40 mm
Speed:
Other data:
Control voltage 24 V DC
Contour check consists weight control, control of dimensions of the load and pallet base control.
Weight control is checking that the load is not exceeded. It is usually integrated in the contour check assembly.
Pos. Name
1 Base frame
2 Guiding set
3 Weighting set
1 2
Base frame in anchored to the ground. Conveyor is attached from the upper side.
Guiding set is anchored to the floor and it prevents damages of weighting sensors due to horizontal forces.
Weighting set is enabling leveling of the device and takes care that load is equally distributed on all 4
weighting sensors.
Control of dimensions is used for checking that load dimensions are not exceeded.
Pos. Name
1 Frame
2 Height control
3 Width control
4 Length control
3
2
Pallet base control is checking empty area of the pallet where the pickup forks are reaching. It is usually integrated in
the contour check assembly.
Pos. Name
1 Base frame
2 Guiding wheels
3 Flags
4 Supporting wheels
5 Sensors
Shuttle with two roller conveyors with inclination on board is transporting pallets longitudinal along the warehouse
from the input place till the output place. It stops automatically at the desired position where the symmetry of the
roller conveyors of the shuttle are aligned with the symmetry of the input or output conveyors.
Shuttle is running on the longitudinal rails (standard IPE profiles). Running and guiding wheels are made of Vulkolan.
Driving motorgearbox is connected on two of the running wheels with cardan shafts.
Pos. Name
1 Shuttle Frame
2 Driving wheel set with guiding wheels
5 Driving wheel set
6 Driven wheel set
7 Driven wheel set with guiding wheels
8 Control cabinet
9 Current collector
10 End switches
12 Roller conveyor with inclination
13 Roller conveyor with inclination
14 Driving motorgearbox
15 Hydraulical buffer
16 Kardan Shaft
Shuttle frame is made out of steel plates and standard tubes with machined connecting surfaces for connection with
other shuttle components.
Driving set is assembled from driving shaft, running wheel, housing units with bearings and frame. Running and guiding
wheels are made of vulkolan. Guiding wheels are set on eccentric shafts which allows adjustment of the wheels.
Driving unit is asemmbled of motorgearbox and 2 kardan shafts whish are connected to the shafts of driving
wheels.Gearbox is fixed directly to the shuttle frame.
Hydraulical bumpers (one on each side) are fixed to the shuttle frame. They prevent damages of the shuttle elements in
case of failure when shuttle runs over the end limits.
There are two roller conveyors with tilting mechanismus on board. Roller conveyor is described in the Chapter 2.4.1.3
Roller conveyor carrier is monted on rotating bearings. Tilting is enabled with eccentrical mounted shaft mounded on
the tilting motorgearbox. By turning of the eccentric shaft, tilting table is moved upwards or downwards together with
roller conveyor thus enabling inclination of the roller conveyor.
Capacity 2x10 kN
Shuttle dimensions
Height 2.207 mm
Width 1.300 mm
Speed:
Acceleration:
Other data:
Control voltage 24 V DC
Shuttle drive:
Type K89-LE160MF4EF-L150NHA-IN
Output torque 565 Nm
Motor revolutions 1.440 r.p.m.
Gearbox revolutions 184 r.p.m.
Ratio 7,97
Voltage 400 V
Power 11 kW
Roller conveyor drive:
Type BF39-LE80MD4E-L16N
Output torque 79 Nm
Motor revolutions 1.440 r.p.m.
Gearbox revolutions 66 r.p.m.
Ratio 21,9
Voltage 3x400 V
Power 0,55 kW
Tilting table drive:
Type FDF39-LA71MH4-L8N-IN
Output torque 190 Nm
Motor revolutions 1.440 r.p.m.
Gearbox revolutions 19 r.p.m.
Ratio 73,93
Voltage 3x400 V
Power 0,37 kW
Shuttle with chain conveyor on board is transporting pallets transverse across the warehouse from the input place till
the output place. It stops automatically at the desired position where the symmetry of the chain conveyor of the
shuttle is aligned with the symmetry of the input or output conveyor.
Shuttle is running on the longitudinal rails (standard IPE profiles). Running and guiding wheels are made of Vulkolan.
Driving motorgearbox is connected on two of the running wheels with cardan shafts.
Pos. Name
1 Shuttle Frame
4 Driving wheel set
5 Driving wheel set with guiding wheels
6 Driven wheel set with guiding wheels
7 Driven wheel set
8 Control cabinet
10 Current collector
11 End switches
12 Barcode reader
15 Chain conveyor
16 Driving motorgearbox
17 Kardan Shaft
18 Hydraulical buffer
Shuttle frame is made out of steel plates and standard tubes with machined connecting surfaces for connection with
other shuttle components.
Driving set is assembled from driving shaft, running wheel, housing units with bearings and frame. Running and guiding
wheels are made of vulkolan. Guiding wheels are set on eccentric shafts which allows adjustment of the wheels.
Driving unit is asemmbled of motorgearbox and 2 kardan shafts whish are connected to the shafts of driving wheels.
Gearbox is fixed directly to the shuttle frame.
Hydraulical bumbpers (one on each side) are fixed to the shttle frame. They prevent damages of the shuttle elements in
case of failure when shuttle runs over the end limits.
Chain conveyor is mounted on the shuttle with adjustable legs which allows us to level the conveyor.
Capacity 10 kN
Shuttle dimensions
Height 2.207 mm
Width 1.300 mm
Speed:
Acceleration:
Drugi podatki:
Control voltage 24 V DC
Shuttle drive:
Type K89-LE160MF4EF-L150NHA-IN
Output torque 565 Nm
Motor revolutions 1.440 r.p.m.
Gearbox revolutions 184 r.p.m.
Ratio 7,97
Voltage 400 V
Power 11 kW
Chain conveyor drive:
Type FZADS49-LE90SG4E-L16N
Output torque 160 Nm
Motor revolutions 1.440 r.p.m.
Gearbox revolutions 65 r.p.m.
Ratio 21,77
Voltage 3x400 V
Power 1,1 kW
2.4.4 Crane
Stacker crane is intended for storing pallets into rack shelves.
On the crane, there are two sets of wheels, one driving set and one free set.
The framework of the bottom carriage is a box shaped profile welded from sheet metals with treated surfaces for fixing
running and leading wheels and for connecting the column of the crane with bottom carriage.
On the wheel set, a running wheel with barrel bearings and the diameter of 400mm is mounted. On the driving wheel
set, there is also an electrically powered furnished drive with momentum lever. Driving force of the crane is transferred
from the drive over shaft and momentum ring to the running wheel. Entire set of leading and running wheels is
designed for simple and quick maintenance. Bearings of running wheels and leading wheels have to be lubricated
regularly.
The column is composed of lower and upper part and screwed together with the pre-stressed screws. Column is made
of rigid, welled full-wall (box shaped) sheet metals with a diaphragm built in. The column is connected with the bottom
girder with the pre-stressed screws.
Along the column, a 140x40mm leading rail in accordance with DIN 174 is fixed with HV screws. The leading rail serves
for vertical leading of the lifting carriage. On the other side, a 50x40mm (DIN 174) leading rail is fixed along the column.
This rail is used for a horizontal balance of the lifting carriage and it is fixed to the column with the HV screws. In the
middle of the column, front side the catching rail is fixed along the column. The catching rail is type T 90.75.16
according to DIN 15311.
On the column backside, a plate for a lifting unit is welled. On one column side, a ladder is fixed stretching from the
floor to the top of the crane. Ladder can be used for intervention access to any height of the lifting carriage and onto
the upper maintenance landing.
Aluminum ladder is fixed on one side of the column. It enables access to the lifting carriage in any position and access
to servicing landing on the top of the crane. In the middle of the ladder, a safety rope is fixed. A safety carriage for
preventing possible falls in depth runs along this rope.
Lifting carriage has rigid framework, welded of sheet metals. On the carriage, guiding wheels are installed, for leading
the carriage along the column. These wheels allow the carriage to be aligned to all directions. Guiding wheels, which
run along the leading rail and which lead the carriage in transversal direction of the passage are type KEHT 90PP brand
H&T and are adjustable over eccentric wheel axles. Guiding wheels running along front and back head surface of the
leading rail and which lead the lifting carriage in longitudinal passage direction are made of metal. They are adjustable
over eccentric wheel axles and have a lubrication nipple built-in.
Lifting carriage is protected against falling with an automatic holding mechanism for the case of the lifting rope
breakdown or failure of the electromotor drive. On the lifting carriage, a grip jaw is fixed. The jaw is connected to a
speed regulator with a steel rope. If the rate of descent of the lifting carriage is exceeded, the speed regulator activates
the grip jaw, which blocks the lifting carriage movement along the steel leads. In order to unblock the jaw (after the
repair), perform a manual intervention, and manually direct the lifting drive up with low speed. Unblocked brake is
immediately functional.
On the lifting carriage arm, double deep telescopic forks are screwed with eight M16 bolts. The forks have two motors,
brand SEW. One motor drives forks to the first depth and the other motor drives forks to the second depth.
Upper girder has a box-shaped profile welded from sheet metals with treated surfaces for fixing upper leading wheels
and rope wheels. On the upper girder, pulleys with diameters of 630mm and crane upper guiding wheels are situated.
On the top of the column, a service landing is screwed enabling maintenance and replacement of the upper guiding
wheels or interventions on the pulleys.
Lifting unit is made of one steel rope, led over pulleys on to the upper girder, to the lifting carriage, where it is fixed.
The steel rope is driven from the electromotor drive with one drum. The rope drum is made of steel tube and has right
thread. The electromotor drive is fixed on the steel plate on the backside of the column. There is a maintenance
platform under the lifting unit. It enables visibility of the rope during entire working time, and makes visual inspection
easier.
Cable chain, which is attached to the lifting carriage and fixed on the middle of the column, runs along the entire
column height and it is guided with the channels over the whole traveling length. The cable chain type is 27i.12.200.0
brand IGUS. The cables in the cable chain are used for the connection between the lifting carriage and the control
cabinet.
Mechanism of the speed regulator is built-in the lifting carriage and connected over steel ropes to the speed regulator.
If the descending rate of the lifting carriage is exceeded, speed regulator activates grip jaws over the steel rope and the
mechanism. The jaws hold special leads on the column (safety brake rail) and stop descending. Mechanism is
A bracket with a limit switch type 3SE5 112-OCH01, brand SIEMENS and with two magnetic switches type BN 310-2rz,
brand SCHMERSAL, is screwed to the bottom girder. The limit switch controls the end position (before the impact with
the bumper) of the stacker crane. The position of the magnet, that initiates the magnetic switch, is determined, so that
the crane impacts the hydraulic bumper with 70% of his maximum speed. Each side of the corridor has its own magnet
and its own magnet switch. The magnets are placed on the c-profiles and they can be adjusted for about +/- 500mm.
The assembly accessories were used during the crane installation. The buyer should keep one set of these accessories
for a possible disassembly purpose.
The optical data transmission device that is on the crane is placed on an adjustable bracket that is screwed under the
lifting unit platform. The stationary optical data transmission device is placed on a stand at the end of each corridor.
The type of the data transmission device is ISD 400, brand SICK.
Each lifting carriage has a frame made of aluminium profiles. On these profiles, different sensors are attached. There
are also three brackets, made of bended sheet metal. They are placed along the forks and used to carry some additional
sensors and holders with reflectors. These brackets are strong enough to hold one person and they cover the free space
between the emergency control cabinet and the telescopic forks. The stacker crane has next controls on the lifting
carriage:
Forks occupied control, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK
Load alignment control left, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK
Load alignment control right, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK
Place occupied control left depth-2, sensor type is DS50-P1122, brand SICK
Place occupied control right depth-2, sensor type is DS50-P1122, brand SICK
Place occupied control left depth-1, sensor type is WTB27-3P2461, brand SICK
Place occupied control right depth-1, sensor type is WTB27-3P2461, brand SICK
On the bracket of leading wheels on lifting carriage, a bracket for switches in Y direction is fixed. Bracket holds two
Schmersal BN310_2rz magnetic switches and a Siemens 3SE5 114-0CH01-1AC5 limit switch. Two C profiles are mounted
at the bottom and two at the top of the column. Both top and bottom have a magnet and a limit switch bracket, each
of them can be individually adjusted +/-400mm.
Terminal box is placed on the backside of the column, just near the lifting unit motor. It is easy to access from the lifting
unit maintenance platform. In the terminal box the cables that are coming from the main control cabinet and the cables
that are coming from the cable chain are connected.
The collector arm holds the collectors that are sliding in to the power bus bar. On the same time the collector arm holds
the barcode reader type OLM 100, brand SICK, which is used for x positioning of the stacker crane.
DANGER Before beginning any intervention on to the power bus bar, main switches must be in position
O.
Check the voltage in the power rails before intervention.
Intervention is allowed only to professionally qualified people.
The power bus bar is type VKS 10, brand VAHLE. It is supported with the holding profiles type VPT 10, brand VAHLE. The
holding profiles are screwed to the shelving uprights and at the end of the corridor they are supported by the self-
standing brackets that are anchored to the bottom concrete. Along the entire length of the power bus bar, a strip with
printed barcode is glued at the top of the holding profiles and it is read by the barcode reader type OLM 100, brand
SICK that is screwed on to the collector arm.
DANGER Before beginning any intervention on to the power bus bar, main switches must be in position
O.
Check the voltage in the power rails before intervention.
Intervention is allowed only to professionally qualified people.
Type of crane:
Stacker crane PAA 800kg x 18,96m
Weight of crane 11.550 kg
Load capacity:
Load 800 kg
Construction:
Rail S41
Upper leading U-180
Light passage width 1.500 mm
Rail eccentricity 250 mm
Crane dimensions:
Height 18.886 mm
Length 4.743 mm
Wheel base 3.850 mm
Width 1.388 mm
Running wheel diam. 400 mm
Leading wheel diam. 110 mm
Upper wheel diam. 150 mm
Lift drive:
Gear (1x) K189-LES180ZLJ4EF-L260/145MH-IN
-brand SIEMENS
- nominal power 22 kW
- motor torque 143,41 Nm
- motor revolutions 1465 min-1
- motor frequency 50 Hz
- gear ratio 74,35
- nominal voltage 400 V
- brake momentum 145 Nm
- brake voltage 400 V
- installation shape M4A
Driving unit:
H max: 1800 mm
Operating mode:
Remote Automatic
Semi-automatic
Local Semi-automatic
Manual
Other data:
Control voltage 24 V
Drive voltage 400 / 50 V/Hz
Start-up power 37 kW
Besides power and control system there are numerous sensors used to run the system correctly and to avoid dangerous
situations.
INFORMATION The control circuits 230 VAC and 24 VDC are not affected by the main rotary switch.
2.5.4.2 Shuttle
The power supply shuttle is implemented from electrical cabinet +SB1 to enclosed rail system that consists of 6-pole
(5+PE) conductor copper strip (bars) 60A. Two current collectors are placed on the vehicle frame and provides power
supply to the machine which is further transmitted to the cabinet +L01 to the main rotary switch. This switch and +SB1-
(7Q1 and 8Q1) circuit breaker enables or disables the power for the frequency supply modules, frequency drives (motor
modules) and motors.
INFORMATION The control circuits 230 VAC and 24 VDC are not affected by the main rotary switch.
Main cabinet +SB2 consists of two cabinets and it is standing beside +SB1. It contains all executive and safety
components of the electrical equipment which controls conveyor system. From this cabinet all freguency regulated
motors and motors driven over contactor are controlled. It also includes control system Simatic S7-1500 for conveyor
system. Communication is based via Profinet communication protocol.
2.5.5.1.2 +CP301
Small cabinet +CP301 is connected with main cabinet +SB2. It is cabinet with only control voltage and contains
decentralized peripheral module (ET200MP) on which are connected special safety peripheral modules SDI and non-
saftey DI/DO modules. All sensors, safety grids, buttons, stop buttons, safety door locking switches and signaling lights
in that area are connected to the modules, respectively to the ET200MP module. Module is connected to main cabinet
+SB2 via Profinet communication. Frequency driven motors and motor driven over contactor are controlled from the
main cabinet +SB2, where regulators and contactors are located.
2.5.5.1.3 +CP502
Small cabinet +CP502 is connected with main cabinet +SB2. It is cabinet with only control voltage where power is
directed to 24VDC by power supply unit. It contains decentralized peripheral module (ET200MP) on which are
connected special safety peripheral modules SDI and non-saftey DI/DO modules. All sensors, safety grids, buttons, stop
buttons, safety door locking switches and signaling lights in that area are connected to the modules, respectively to the
ET200MP module. Module is connected to main cabinet +SB2 via Profinet communication. Frequency driven motors
and motor driven over contactor are controlled from the main cabinet +SB2, where regulators and contactors are
located. In front of the cabinet operating touch panel is mounted.
All cabinets (+SB2, +CP301 and +CP502) are equipped with lighting which turns on when the doors are opened. Air-
condition with filters are used for eliminating excessive heat.
All components in the cabinets are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinets. Cable entries to the cabinets
are at the bottom. All connections in the cabinets are accomplished with flexible conductors of a proper cross section,
proper color and insulation. All cable ends are terminated with suitable cable terminators. End of each conductor is
labelled with marking rings with a clamp label, marking which clamp the conductor is connected to.
2.5.5.2 Cranes
Main cabinet +L01 is fixed on the column on the back side of the crane. All executive and safety components of the
electrical equipment and the controlling computer which control the machine are located in the main cabinet. The
cabinet is equipped with lighting, which turns on when the doors are opened. Fan units with filter are used for
conveying excessive heat.
All components in the cabinet are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinet. Most of the cable enters the
switch cabinet from the bottom hatch. Several smaller cables go through cable glands on upper surface. All connections
in the cabinet are accomplished with flexible conductors of a proper cross section and proper color insulation. All cable
ends are terminated with suitable cable terminators. End of each conductor is labeled with marking rings with a clamp
label, marking which clamp the conductor is connected to.
Main rotary switch on +L01 is placed on the left side cabinet door, emergency stop button is placed on the right side
cabinet door.
+L02 is smaller cabinet on the lifting carriage which is connected with the main cabinet using high flexible cables in a
power chain. Decentralized peripheral module (ET200MP) is connected to the +L01 main cabinet via Profinet
communication. All sensors on the table (lifting carriage) are connected to the DI/DO/AI modules, respectively to the
ET200MP module. Frequency driven motors on the lifting carriage are controlled from the main cabinet where the
regulators are located.
Touch panel is located in the lifting cabin. It is used for operating the crane
2.5.5.3 Shuttles
Main cabinet +L01 is fixed on the vehicle. All executive and safety components of the electrical equipment and the
controlling computer which control the machine are located in the main cabinet. The cabinet is equipped with lighting,
which turns on when the doors are opened. Fan units with filter are used for conveying excessive heat.
All components in the cabinet are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinet. Most of the cable enters the
switch cabinet from the bottom hatch. Several smaller cables go through cable glands on upper surface. All connections
in the cabinet are accomplished with flexible conductors of a proper cross section and proper color insulation. All cable
ends are terminated with suitable cable terminators. End of each conductor is labeled with marking rings with a clamp
label, marking which clamp the conductor is connected to.
Main rotary switch on +L01 is placed on the left side cabinet door, emergency stop button is placed on the right side
cabinet door.
2.5.6.1.1 Drives
Chain conveyor
Roller conveyor
Lifting table
Vertical adjustment
Excenter lifting
Motors are frequency regulated or driven over contactor. For frequency regulated motors Sinamics G120C frequency
converters are used. They are located and powered in main cabinet +SB2.
Cabinet lights
Power sockets
Fan units for heating
2.5.6.2 Crane
2.5.6.2.1 Drives
TRAVEL DRIVE
Crane is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
HOIST DRIVE
One motor lifts the carriage platform driving one steel rope cable drum along Y-axis. Motor is powered by one Sinamics
motor module that moves machine along the isle. Motor module it is located and powered in main cabinet +L01.
Lifting carriage is comprises 2 motors with forks. Each motor is for one fork depth. First motor is for single depth and
second motor is for double depth. Motors are powered by one Sinamics double motor module that moves forks in
single or double deep racks to get the pallet. Motor module it is located and powered in main cabinet +L01. Motors are
powered with flexible cables placed in the plastic chain.
230VAC source it is located in main cabinet +L01 and on the machine construction, powered from small cabinet +L02:
Cabinet lights, power sockets and fan units for heating are located in +L01
Reflector, rotating beacon and horn are located in +L02
2.5.6.3.1 Drives
TRAVEL DRIVE
Shuttle is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
There are two roller deck platforms, located on the shuttle, each with one motor. Motors are powered by one Sinamics
double motor module. Motor module it is located and powered in main cabinet +L01.
HOIST DRIVE
On each roller deck platform motor for hoist is located. Motors are powered by one Sinamics double motor module.
Motor module it is located and powered in main cabinet +L01.
Cabinet lights
Power sockets
Fan units for heating
Rotating beacon
Horn
2.5.6.4.1 Drives
TRAVEL DRIVE
Shuttle is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
Conveyor deck platform is located on the shuttle. Conveyor motor is powered by one Sinamics motor module. Motor
module it is located and powered in main cabinet +L01.
Cabinet lights
Power sockets
Fan units for heating
Rotating beacon
Horn
PLC
ET modules
Switch
Optical communication for vehicles
Frequency converters control
Sensor devices
Signaling lights
Panel
2.5.7.2 Cranes
In main cabinet +L01 power is directed to 24VDC by power supply unit. Control voltage circuits supplies:
Since small cabinet +L02 doesnt have its own 24 VDC power supply, it is provided from +L01 via power chain. It
supplies ET200MP control module with belonging DI/DO modules, sensors on lifting carriage and signaling lights and
panel in enclosure +L03.
2.5.7.3 Shuttles
In main cabinet +L01 power is directed to 24VDC by power supply unit. Control voltage circuits supplies:
2.5.8 Sensors
Sensors with functions are very important for the system functionality.
Sensors installed in the safety circuits have function to trigger the safety PLC which is located in main cabinet +SB2.
Their intention is to stop movable parts in case of danger. Safety signals are connected to the special safety input
modules connected to the ET200MP, which further transmits signals to the safety PLC. There are several types of safety
sensors installed in conveyor system:
Optical reflective sensors: For occupancy, gap control, slow an stop position
Barcode reader: For scanning barcode type on the pallet
Proximity sensors: For position detection of lifting table, vertical adjustment and excenter lifting conveyors
Light grids: For detection of the pallet dimensions.
2.5.8.2 Cranes
Sensors installed in the safety circuits have function to bring the machine to a safe state. When safety circuit is
interrupted 24VDC from motor modules is taken away which cause safe stopping the moving motors and other
movable parts:
Rope brake up sensor and sensor for catching device: In case of lifting carriage drop
Safety doors switch: To prevent vehicle movement in case of enter the protected area
Mechanical safety switch: Prevent further movement of the machine
Load cells: Weight control
Cabin safety door switch: To prevent movement of the machine in case opened cabin doors
Optical reflective sensors: For occupancy, gap control and forks depth
Optical sensors: For linear positioning in x and y direction via 2D barcode type
Magnetic sensors: For slowing down vehicle before safety end position is reached
2.5.8.3 Shuttles
Sensors installed in the safety circuits have function to bring the machine to a safe state. When safety circuit is
interrupted 24VDC from motor modules is taken away which cause safe stopping the moving motors and other
movable parts:
Safety doors switch: To prevent vehicle movement in case of enter the protected area
Mechanical safety switch: Prevent further movement of the machine
Optical reflective sensors: For occupancy, gap control and forks depth
Optical sensors: For linear positioning in x direction via 2D barcode type
Magnetic sensors: For slowing down vehicle before safety end position is reached
2.5.9 Communication
Communication with the system and external world is implemented:
Frequency regulated motors in conveyor system are implemented through Profinet communication connected
to PLC in main cabinet +SB2.
Cranes and shuttles are implemented through SICK ISD400 optical data transmission. One unit is on the vehicle
connected to Simotion D425, second unit is placed parallel on construction and connected to PLC in main
cabinet +SB2
System communication is used for the data communication with other (higher level) devices (MFC).
For decentralized periphery units and the operator panels (HMI) Profinet connection it is used..
Automatic power supply switch-off is implemented by connecting exposed parts of the device to a protective conductor
and by equalizing main potentials. Protective conductors are in yellow-green color. All protective conductors must be
connected to a special collector in the distribution cabinet, which is connected to the protective ground
Protective devices for over-current protection (fuses, switches, etc.) execute automatic defect current cutout.
Disconnection device, which is built in the installation or in parts of the installation, must automatically uncouple power
supply to the part of installation, which is protected by this device
Protection against electric shock must be verified with measurements after the installation and also later during regular
inspections and periodic measurements
Usage of a SELV (Safety Extra Low Voltage) of 24 V is used as an additional protective measure.
Cables are placed in protective tubes and properly located to prevent mechanical damages.
In the distribution cabinets, non-insulated parts must be covered with an insulating material (connecting terminals,
switches, etc.).
INFORMATION Every emergency stop button does not stop the whole system. See Heading 5
INFORMATION There is no option to bypass Emergency stop push-buttons, as well as door switches. Only limit
switches bypassing is possible.
For position control of vehicles is used barcode positioning system. End positions are detected by mechanical limit
switches, connected into the safety circuit. Before the end position is reached, a magnetic sensor reduces the speed of
the vehicle.
Vehicles are positioned to the warehouse place based on the readings of the incremental encoder for the gantry and
hoist (only for cranes) drive. Forks (only for cranes) are positioned into the rack on the readings of the absolute
encoder.
The applicative software on the conveyor system controller enables autonomous operation.
communication to the higher-level system (task management, status reports, alarm reports),
task execution in automatic mode,
execution of simple movements in manual and backup (service) mode,
control of device state and safe stop in case of error,
control of functions of conveyor system equipment,
control of frequency regulators,
communication with the user (HMI),
coordination of take-off and delivery to the connected systems,
control of load presence and position,
checking site occupation,
diagnostic of errors and generation of alarm messages,
immediate stop in case of abnormal states or events.
communication to the higher-level system (task management, status reports, alarm reports),
task execution in automatic mode,
execution of simple movements in manual and backup (service) mode,
control of device state and safe stop in case of error,
control of functions of vehicles equipment,
control of frequency regulators,
communication with the user (HMI),
coordination of take-off and delivery to the connected systems,
control of load presence and position,
checking site occupation,
checking vehicles speed,
diagnostic of errors and generation of alarm messages,
immediate stop in case of abnormal states or events.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
1. Heightand leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
Chain can be tensioned by screwing the tensioning nut (1) on the driving station. In case there is no more space for
tensioning, chain needs to be shortened!
H:L ~ 1:100
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearbox and check oil sealing
on the drives.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
1. Heightand leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the rollers and gearbox and check oil sealing on
the drives.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
1. Heightand leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the rollers and gearbox and check oil sealing on
the drives.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
2. Control of the correct tension of the driving chain (1). Tension of the driving chain can be adjusted with moving
of the gearbox holding plate together with gearbox.
3
2 1
Figure 4.14 Adjusting of the lifting mechanismus
3. Paralel running of the front and back eccentric arms. This can be achieved with shorthening or lengthening of
the arms (2)
4. Adjusting of the turning the limiter
With setting of the bolt (3), turning angle can be limited in both directions
Before startup, complete device must be checked if every parts are fixed, check smootnes of running of all moving
parts. After startup, device should run for 10 min. Carry out sound control of the bearings and gearbox and check oil
sealing on the drives.
4.1.5 Stopper
Handling during lifting a cargo is allowed only to qualified personal!
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
2. Control of the correct height of the stopper. The height can be adjusted by shortening of the arm (1).
Before startup, complete device must be checked if every parts are fixed, check smootnes of running of all moving
parts. After startup, device should run for 10 min. Carry out sound control of the bearings and gearbox and check oil
sealing on the drives.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
2 1
6. Set sensors.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
1. Height and levelling of the conveyor must be checked (measure X distance between upper side of the rail
profiles and upper side of the roller).
Conveyor must be levelled by adjusting of the levelling nuts (1) in order to reach desired height and alignment
with pickup conveyor. For levelling, water scale should be used
2. Control of running of the driving wheels and setting of the guiding wheels
1 2
Shuttle must run straight without causing side forces on the guiding wheels. This must be ensured by alignment of the
running wheel sets and with setting of the guiding wheels.
Guiding whels are mounted on the eccentric shafts which enables us to set the clearance between guiding wheels and
the guiding surface of the rail. Each guiding wheel must have 0,5 mm of the clearance.
Optimal running of the shuttle is achieved when contact with rail is exchangeing between inner (2) and outher (1)
guiding wheel. If only one of the guiding wheels is in contact all the time, that means that shuttle is inclined and it shoul
be aligned again.
4. Control of the roller conveyors is described in the chapter of the roller conveyor.
6. General control
Check lubrication of the bearings, oil level in the gearboxes and all bolts.
Before startup, check complete shuttle if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearboxes and check oil sealing
on the drives.
DANGER While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
1. Height and levelling of the conveyor must be checked (measure X distance between upper side of the rail
profiles and upper side of the chain).
Conveyor must be levelled by adjusting of the levelling nuts (1) in order to reach desired height and alignment
with pickup conveyor. For levelling, water scale should be used.
2. Control of running of the driving wheels and setting of the guiding wheels
1 2
Shuttle must run straight without causing side forces on the guiding wheels. This must be ensured by alignment of the
running wheel sets and with setting of the guiding wheels.
Guiding whels are mounted on the eccentric shafts which enables us to set the clearance between guiding wheels and
the guiding surface of the rail. Each guiding wheel must have 0,5 mm of the clearance.
Optimal running of the shuttle is achieved when contact with rail is exchangeing between inner (2) and outher (1)
guiding wheel. If only one of the guiding wheels is in contact all the time, that means that shuttle is inclined and it shoul
be aligned again.
3. Control of the Chain conveyor is described in the chapter of the chain conveyor.
5. General control
Check lubrication of the bearings, oil level in the gearboxes and all bolts.
Before startup, check complete shuttle if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearboxes and check oil sealing
on the drives.
4.4 Crane
4.4.1 Transportation and installation
Handling during lifting a machine is allowed only to qualified personal!
ATTENTION Stacker crane should only be unloaded, transported and installed by a relevant service!
DANGER While loading or unloading, avoid strokes. Dwelling under lifted cargo is strictly forbidden!
INFORMATION For lifting, transportation or carriage use suitable bores, grooves or transport ears, designed for
such purposes.
Automated machines are taking care of storing and retrieving of the goods. In each aisle, there is a crane (automatic
storage retrieval machine, ASRS) with one deck. For conveying the transport unit to and from the warehouse, there are
also some supporting conveyor tables and two shuttle cars.
1. rack locations,
2. conveyor locations (conveyor tables), and
3. crane and shuttle locations (decks).
W:rr:xx:y:z ,
where
High-bay warehouse comprises of up to 1920 pallet locations per crane. Racks (rr) are always denoted with two-digit
number, where first digit represent the aisle number while the last digit is 1 for the racks on the left and 2 for the racks
on the right, when observing the system from the conveyor side. The pallet storage and retrieval operations are
performed by three stacker cranes, numbered by their aisles from 1 to 3. Aisle numbering as well as the rack denoting
is shown in Figure 5.1.
In the horizontal direction there are 60 locations, numbered consecutively from 1 to 60, starting at the conveyor side.
There are 8 locations in vertical direction. Slots with vertical index 1 are in the lowest position. In the direction of forks
movement, racks closer to an aisle have index 1, while the farthest location has index 2. Each rack window can store
two pallets.
Figure 5.1 Ground plan of the warehouse. Black boxes represent conveyors, light and dark gray box represent slot locations in racks
Tfsn ,
where
f is a functional group: 0 3,
s is a subgroup: 0 2,
n is a conveyor number: 0 4.
Vehicles (cranes and shuttles) pick pallets from delivery conveyors and drop them to dispatch conveyors as given in
Table 5.1Error! Reference source not found..
Cv0n ,
where
Values in parenthesis are given for shuttle 5, which has two decks.
Some examples of warehouse location designations are given Figure 5.2 and Figure 5.3. For crane 1, the designated rack
locations are at level 1, for crane 2 at level 3, and for crane 3 at level 5.
Figure 5.2 High-bay warehouse: top view with designated locations of racks, transport paths, and vehicles
Figure 5.3 High-Bay warehouse: top view with designated locations of gravitational rack system
there is no overhang,
pallet with goods is up to 1800 mm high, and
weight of goods, including a pallet, does not exceed 800 kg.
Format of transport unit barcodes Is PNNNNNNNNN, where character P stands for pallet and NNNNNNNNN presents a
number in range 000000001 999999999.
Figure 5.5):
WMS
(SAP)
MFCS &
SCADA
The vehicles and the conveyor system are fully automated and computer guided. The automation is carried out on
several levels. Sensors, frequency converters, etc. represent the low automation level. These are controlled by the PLC
located either in the electrical cabinet of a vehicle or in the electrical cabinet of the conveyor system. PLCs processes
the input data and command the vehicles and conveyors in order to perform simple commands.
Supervisory control and data acquisition (SCADA) system takes values from PLCs in order to show to an operator the
current status of the system. In also performs logging of some interesting quantities.
Movements of the vehicles and conveyors are performed according to the commands received from MFCS. The main
task of MFCS is to brake the complex commands, received from WMS, to the simple commands, which can be executed
by PLCs. MFCS has to execute the commands received from WMS in such a way to finish the commands as soon as
possible (rearrangement of commands, parallel commands ).
WMS takes care of warehouse organization and business logic. It initiates automatic movements in the warehouse. The
picture of the warehouse (which locations are occupied; which transport unit is stored there) should be handled by
WMS. The optimal placement of goods in the warehouse is very important for efficient movements of transport units
and goods. WMS should also strive to achieve high availability of the system by distributing the similar product to
different aisles. The placement of the goods is done solely by WMS.
The communication between PLCs is implemented by Profinet protocol, while PLCs and MFCS communicate by TCP/IP
telegrams. The communication between MFCS and WMS is performed via web services.
MFCS: 192.168.20.233,
Conveyor PLC: 192.168.10.203,
Crane 1: 192.168.10.10,
Crane 2: 192.168.10.20,
Crane 3: 192.168.10.30,
Crane 4: 192.168.10.40,
Crane 5: 192.168.10.50.
Gateway for all devices is set to 192.168.10.1. Devices communicate with MFC system via ports 2001 and 2002.
The network equipment in the system should be configured to allow network traffic between these devices on the
given ports.
1. Operators must manually put a transport unit to the conveyor table T001.
2. The transport unit is then conveyed to T002. During the movement its barcode is read and physical quantities
are measured.
3. On conveyor T002 the entry of a new transport unit is reported to WMS.
4. On this stage MFCS will perform a task on its own or wait for WMS task:
a. If there is something wrong with the transport unit (no barcode, some dimension is not compliant
with the requirements, etc.) MFCS will report the fault to WMS and on its own send the transport unit
to T005 via T004.
b. For transport units, which are ready for storing, WMS should provide the final position in the
warehouse W:##:##:#:#, where # represents a number. WMS should also make appropriate
reservations to prevent dead-lock situations.
5. When the command is received, the transport unit continues in in the following way:
a. For racks W:1#:##:#:# transport units follow conveyors T002, T110, T111, and T112 where they are
picked by crane 1 (deck C101).
b. For all other racks transport units follow conveyors T010, T011, and T012, where they are picked by
shuttle 4 (deck C401).
6. In case that the transport unit goes to racks W:2#:##:#:#, shuttle 4 (deck C401) deposits it to conveyor T211
from where it continues to T212. For racks W:3#:##:#;#, the transport unit is dropped to conveyor T311 and
then conveyed to T312. Transport unit on conveyor T212 is then picked by crane 2 (deck C201) and transport
unit on conveyor T312 by crane 3 (deck C301). In case that a transport unit goes directly to W:52:##:0:1, it is
dropped to conveyor T021.
7. A crane stores a transport unit to required slot in a rack.
1. WMS should first give a command to move a transport unit from a slot in high-bay warehouse to a slot in
gravitational rack.
2. Crane picks a transport unit from the slot in the warehouse and drops it to the appropriate conveyor: from
W:1#:##:#:# to T121, from W:2#:##:#:# to T221, and from W:3#:##:#:# to T321 or T322.
3. Transport units from T121 and T221 are further conveyed to T122 and T222, respectively.
4. A transport unit from T122 or T222 is transferred to shuttle 4.
5. Shuttle 4 deposits a transport unit from its deck C401 to T021.
6. Based on the commands and optimization performed on MFCS, transport units are further conveyed to T023
or T024 via T022.
7. Transport units on conveyors T023 and T024 as well as transport units on conveyors T321 and T322 can be
simultaneously picked by shuttle 5 on decks C501 and C502 and finally dropped to the gravitational rack
W:52:##:0:1
It is also possible to directly move a transport unit from input to W:52:##:0:1. In this case steps 1-4 and 5b of inbound
traffic must be completed first, and are then followed by steps 5 7 of outbound traffic.
Additionally, it is possible to automatically move transport units from slots W:1#:##:#:# to slots W:2#:##:#:# or
W:3#:##:#:# and from slots W:2#:##:#:# to slots W:3#:##:#:#.
Movements of transport units from slots W:2#:##:#:# to slots W:1#:##:#:# or from slots W:3#:##:#:# to slots
W:1#:##:#:# or W:2#:##:#:# can only be made in two phases by generating two WMS commands:
with the first command they should be send to the gravitational rack and
after reentry on the input line (entry notification on T002) to the final destination.
The order of task execution is important only on vehicles. Here MFCS will execute commands based on priority, WMSID
and vehicle performance:
When a vehicle gives a transport unit to a conveyor line or to a rack slot, it can immediately start with
execution of the next command.
When a vehicle finishes the current operation, it will first start executing the feasible commands with the
highest level of priority. If there are many commands with the same priority level, the commands will be
executed in such a way to optimize the vehicle movements.
It can happen that a task fails due to poor handling, a rack slot empty, a rack slot full, a conveyor full, etc. In such
situations command on MFCS should be canceled and then new command from MFCS or WMS issued.
5.4.1 Layout
The conveyor system transfers pallets to and from the vehicles in the warehouse. It is divided to segments to allow for
fluent operation. A segment is a group of conveyor tables. The conveyor tables, as schematically presented in Error!
Reference source not found., are grouped in segments according to Table 5.3.
The pallet entry is where the pallets enter the automatic warehouse. When a new pallet is placed on conveyor T001, it
starts moving to T002. During this move, the pallet dimensions and weight are checked. If the measurements are within
the specified tolerances, the pallet continues towards one of the vehicles, otherwise it is rejected and sent to the error
lane (T004 and T005).
From the warehouse, the pallet can be sent to the output in the following ways:
from W:1#:##:#:# via crane 1 (C101), segment T12, shuttle 4, segment T02, shuttle 5,
from W:2#:##:#:# via crane 2 (C201), segment T22, shuttle 4, segment T02, shuttle 5,
from W:3#:##:#:# via crane 3 (C301), segment T32, shuttle 5.
5.4.2.3 Aligner
An aligner is used where a pallet needs to be aligned before it can travel further. This is done by rising the aligner in a
pallet travel path direction. The motor that drives the aligner is controlled directly. An aligner is equipped with two
inductive sensors that detect when the aligner is in the upper or lower position.
Turn the switch +SB1-1Q1 on the main power cabinet (Figure 5.6) to positon ON.
Turn the switch +SB1-1Q1 on the main power cabinet to positon OFF.
When the main power cabinet is switched on, the whole conveyor system is also powered.
E-stop safety buttons on cabinets CP001, CP101, CP201, CP301, CP401, CP501, or CP502.
When all E-stop safety buttons are pulled out, it is possible to reset the system and start the movement again.
The safety relay uses two channel safety system. In cases when the emergency stop condition is lost only for very short
time period (pressing and quickly releasing mushroom safety button, quickly opening and closing a door, ) it may
happen that only one channel is lost and the safety contactor cannot be reset. Remedy is to press the E-stop button and
only release it after a few seconds.
local and
remote,
designated with pictograms in Figure 5.7. The mode of operation is valid for all conveyor tables in the segment.
In local mode the system operates by manually pressing the corresponding buttons on operators panel or buttons,
while in automatic mode, MFC system sends corresponding commands.
A box around the conveyor tables represents a segment. The status of segment is represented with the color as follows:
To change the mode of operation, the operator has to press the pictogram (Figure 5.7), usually located in the top left
corner of a segment.
MFC system can operate with a segment only when it is in remote mode of operation. When in remote mode, the
operator cannot control a segment. All the movements of conveyors, lifting tables, and aligners are performed
automatically.
To work manually with a selected segment, it must be first put to local mode. When segment in local mode, the user
has to select the conveyor tables which he wants to manipulate. The box near a table can be empty, which means it is
not selected, or can display a checkmark, which means it is selected for operation (Figure 5.11, top left). The status can
be changed by pressing a box on the screen.
At the same time, an operator can select more than one unit. It is even not necessary that units are included in the
same segment. All units with checkmarks will move simultaneously. To trigger a movement, the operator has to keep
pressed an appropriate button (Figure 5.12):
When dimension check fails, a pallet is conveyed from table T002 over table T004 to table T005. When on table T005, a
dimension check screen pops-up (Figure 5.13), which shows why a pallet was rejected. Possible reasons are:
When operators takes a pallet from T005, the statuses are cleared.
3 2 4
5 7
Information about a pallet on conveyor table T005 can also be displayed by pressing F7 button (Figure 5.12).
When an alarm appears, the corresponding segment goes to alarm state. Besides, alarm icon above F10 button (Figure
5.12) starts to blink.
By pressing F10 button, an alarm screen (Figure 5.14) opens with detailed information about the active errors.
To reset an alarm, the operator must first remove the reason for it, and then press F10 button (when on the alarm
screen) or press a reset button on a cabinet.
Possible alarms, accompanied with possible causes and remedy are given in a separate chapter.
5.4.5.1.5 Settings
5.4.5.1.6 Permissions
Some functions of the main panel are only available with elevated user permissions. When an operator requests such a
function, for example access to the settings screen, the login screen (Figure 5.16) pops-up.
user: yag
password: yag
After entering the correct user and password, an operator must request the required function again.
In all cases the segment is composed of two conveyors. To operate in local mode:
an operator must first switch a segment in local mode; in Figure 5.18 one has to put the switch to the right
position,
then, by pressing buttons with conveyor designation, the conveyor starts to move in predetermined direction.
To go back to remote mode, an operator has to turn the switch back to the left position.
2 Tfsn material missmatch Sensor and data information on conveyor Tfsn differ
3 Tfsn running too long conveyor Tfsn motors for rollers or chain are running too long. There must be some
problem with sensors or improper material handling. Check the positions of
pallets in the warehouse and on MFC and adapt accordingly.
4 Tfsn running too long hoist Tfsn hoist motor (lifting table, aligner) is running too long. Check the position
of sensors.
5 Tfsn limit switch Tfsn limit switch is crossed. Adjust the positon of switches used in normal
operation.
6 Tfsn not ready (xxQ1, yyF1) Tfsn motor is not ready. Check the listed elements (motor protections, fuses,
frequency inverter).
7 MFC queue full There is no communication between conveyor system and MFC. MFC can be
down, or connection is lost. Cehck cabling.
8 TCP IP chanel fault Connection between MFC and conveyor system is lost. MFC can be down,
check cabling.
9 Phase alignment There is a problem in power supply. Check all three phases.
10 c101 main switch (2Q1) Crane 1 (C101) is switched off. Switch it on.
11 c201 main switch (3Q1) Crane 2 (C201) is switched off. Switch it on.
12 c301 main switch (4Q1) Crane 3 (C301) is switched off. Switch it on.
13 c401 main switch (7Q1) Shuttle 4 (C401) is switched off. Switch it on.
14 c501 main switch (8Q1) Shuttle 5 (C501, C502) is switched off. Switch it on.
15 Conveyor main switch (5Q1) Conveyor main switch is off. Switch it on.
16 Conveyor 24V (6Q1) Protection 6Q1 tripped. Remove the reason and set it back.
17 Main cabinet ventilation (13F2) Fuse 13F2 tripped. Remove the reason and set it back.
18 Sensors 24V (14F4) Fuse 14F4 tripped. Remove the reason and set it back.
19 Frequency regulator 24V (14F5) Fuse 14F5 tripped. Remove the reason and set it back.
20 Cp502 fuse, main cabinet (15F2) Fuse 15F2 tripped. Remove the reason and set it back.
21 Cp502 24V fuse (124F4) Fuse 124F4 tripped. Remove the reason and set it back.
22 Cp502 ventilation (125F1) Fuse 125F1 tripped. Remove the reason and set it back.
23 (Segments T00, T01, T03, T11, T12) Stop button is pressed. When there is no danger, release it and reset the
stop button CP001 system.
24 (Segments T00, T01, T03) safety Stop button is pressed. When there is no danger, release it and reset the
contactor out (12k1) system.
25 (Segments T11, T12) stop button Stop button is pressed. When there is no danger, release it and reset the
CP101 system.
26 (Segments T11, T12) safety Stop button is pressed. When there is no danger, release it and reset the
contactor out (12k2) system.
27 (Segments T21, T22) stop button Stop button is pressed. When there is no danger, release it and reset the
CP201 system.
28 (Segments T02, T21, T22, T31) stop Stop button is pressed. When there is no danger, release it and reset the
button CP501 system.
29 (Segments T21, T22) safety Stop button is pressed. When there is no danger, release it and reset the
contactor out (12k3) system.
30 (Segment T31) stop button CP301 Stop button is pressed. When there is no danger, release it and reset the
system.
31 (Segment T31) safety contactor out Stop button is pressed. When there is no danger, release it and reset the
(12k4) system.
32 (Segment T32) stop button CP321 Stop button is pressed. When there is no danger, release it and reset the
system.
33 (Segment T32) safety contactor out Stop button is pressed. When there is no danger, release it and reset the
(12k6) system.
34 (Segment T02) safety contactor out Stop button is pressed. When there is no danger, release it and reset the
(12k5) system.
35 (Segment T02) safety contactor out Stop button is pressed. When there is no danger, release it and reset the
(12k5) system.
36 ET200 CP301 unreachable There is no Profinet communication with ET200 module in CP301. Check if
there is power supply, check cabling.
37 ET200 CP502 unreachable There is no Profinet communication with ET200 module in CP502. Check if
there is power supply, check cabling.
38 CLV620 unreachable There is no Profinet communication with barcode reader CLV620. Check if
there is power supply, check cabling.
39 Frequency regulator Tsfn There is no Profinet communication with frequency inverter for table Tsfn.
unreachable Check if it has power supply, check cabling.
40 Crane x unreachable There is no Profinet communication with Crane x. Check if it is powered on.
Check the cabling, optical communication.
41 Shuttle x unreachable There is no Profinet communication with Shuttle x. Check if it is powered on.
Check the cabling, optical communication.
Turn the switch +SB1-2Q1 (Crane 1), +SB1-3Q1 (Crane 2), +SB1-4Q1 (Crane 3) on the main power cabinet to
position ON.
Turn the switch +L01-402Q1 on the crane main cabinet +L01 to position ON.
Turn the switch +L01-402Q1 on the crane main cabinet +L01 to position OFF.
Turn the switch +SB1-2Q1 (Crane 1), +SB1-3Q1 (Crane 2), +SB1-4Q1 (Crane 3) on the main power cabinet to
position OFF.
Safety switches, which limit the cranes movement area: travelling (408S1), hoisting (427S1), the speed
regulator switch (408S2) and the catching jaws (427S2).
Mushroom safety button on main cabinet (409S1).
Operators cabin doors on the lifting carriage (428S1, 428S2).
Doors for accessing the crane area from conveyor side or opposite side.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the crane, he needs to open a door to the aisle first and afterwards he also opens a door to
the cabin. The faults on the crane can be reset and crane locally operated only when the safety is re-established. To
do this, the operator must press the reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
Local regime is used, when operator needs to control crane from operators cabin or when access to crane aisle is
needed to disable in attentional automatic crane movement. When crane is in local regime it can operate only in
manual or semi-automatic mode from the panel.
Remote regime is crane operating regime, when crane is controlled remotely by MFCS.
In manual mode, all movements of the crane and the lifting carriage are made by pressing the respective buttons on
the operators panel. In semi-automatic mode, a crane itself performs a simple operation that consists of a movement
to the selected location, loading of a material from that location, or the depositing of material to it. Manual or Semi-
automatic mode can be selected from the operators panel and are enabled only in local regime.
The control regime is signaled on the operators panel and on MFCS PC.
Key on the small enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
The local regime is enabled only when the key-locks are set in the following ways:
The remote regime is enabled only when key-locks are set as follows:
When crane is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, crane will finish current task and then stop. Crane will not start
executing next task to allow entrance to crane aisle. Always wait to crane finishes current to, otherwise automatic reset
could not be possible and manual intervention will be needed. When crane is stopped, key can be turned to LOCAL
position.
In all other key positions crane is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Switch key to AUTO FINISH on small enclosure and wait till crane finishes current task.
Led light for operation on small enclosure should be off, in case that led light is on or blinking, operator
should wait that crane finishes the current task.
When crane is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the lifting carriage cabinet to LOCAL position.
Now the crane is in LOCAL regime and after resetting the faults, it can be operated from the operators panel.
Remove a pair of keys from the key-lock on crane cabinet; this is only possible when the key-lock is switched
to REMOTE position.
Leave the crane and close the door to the aisle.
Put the pair of keys to the key lock in small enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the crane is completely autonomous, and its movements are unpredictable.
5.5.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.21. They represent:
Physical position is given as a numbered value, presenting coordinates in millimetres: Cranes horizontal and
vertical position and forks single deep and double deep position.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (slot in a rack, conveyor) designated with four indices giving the logical coordinate.
5.5.4.2.1 Buttons
There are six buttons on top of the main screen as shown in Table 5.4. With pressing button operator change screen or
execute an action.
Button Action
Opens the crane manual operation screen, for a detailed description check Chapter 5.5.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.5.4.4.2
Opens the crane sensor screen, for a detailed description check Chapter 5.5.4.35.5.4.3.
Opens the alarm screen on which we display all the alarms, as shown Figure 5.22. If an alarm
is present the button flashes red.
If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit crane parameters.
The first icon represents crane regime, on the icon is seen which device can control the crane. There are three different
icons of which two are used for displaying the controlling partner, as shown in the Figure 5.23.
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys arent in appropriate positions. Crane movement is not possible.
Crane is in local regime and can be controlled via the operators panel.
Crane mode is displayed via assorted buttons background colours as shown in Figure 5.25.
Colour meaning:
5.5.4.3 Sensors
The sensors screen contains overview of crane sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle. Next to the selected device there are two output fields that are visible only if the
crane is occupied. The first one displays which device is occupied and the second displays the barcode.
5.5.4.3.1 Crane
5.5.4.4 Mode
If the crane is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the crane is controlled via the operators panel as explained in the Chapter 5.5.4.2, then the operator can set control
mode by clicking the button for local mode, or button for semi-automatic mode.
5.5.4.4.1 Manual
First button activates the manual control of the crane. Operator can control crane movement from that screen. Arrows
above physical buttons represent the direction of movement.
F1 Fast speed movement, must be pressed with other action button F1...F7.
F6, F7 Forks movement (F6 toward rack cn2, F7 toward rack cn1).
With button above keys F6 and F7 you can select which forks can be moved. If you want to move one type of fork
(single deep, double deep), other should be on the middle position. Otherwise fork motion is blocked.
Incautious manipulation with the crane in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the crane can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the crane
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.5.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
5.5.4.4.2 Semi-automatic
Button activates the semi-automatic mode, where the operator inputs the desired action and location in the five
input fields. When the start button is pressed the crane start executing requested task.
Input fields:
1. Command, where the operator selects the desired action from a drop-down list. There are four options:
a. - - - - which symbolizes no action is selected
b. Move which symbolizes that the crane will move to the selected location.
c. Pick - which symbolizes that the crane will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the crane will move to the selected location and deposit the material at
that location.
2. Rack, were the entered number is a combination of the crane name and rack identifier (cn1 for left rack, and
cn2 for right rack, where cn is crane number from 1 to 3).
3. Travel, were the entered number represents the desired horizontal location, for the crane (from 1 to 60).
4. Hoist, were the entered number represents the desired vertical location, for the crane (from 1 to 8).
5. Depth, were the entered number represents the depth of the fork (from 1 to 2).
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
Start button.
Cancel button.
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the crane. It is given in terms of two-digit numbers with the
following meaning:
When switching from the manual to the semi-automatic mode the crane is not yet operating automatically, which is
signalized via colour as defined in the Chapter 0. To start the automatic operation, the start button must be pressed. If
the operation was successfully finished and regime not changed, then automatic operation can be continued (is not
reset).
Each time the automatic operation is stared after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the crane stops all actions (automatic operation is lost). After
reset of the faults, the crane continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
The offset for the hoist must be set in such a way, that the distance between the top of fork and the top of the rack
beam is 85 mm when the crane approached the location with GOTO command. See Figure 5.30 for details.
Offset of the travel must be set in such a way, that distance between fork and closest vertical beam of rack construction
is XX mm.
Figure 5.30 Determining the correct position of the crane regarding the horizontal beam. The spirit level is lying on the fork
On the offset screen, shown in Figure 5.31, first enter the location in form of three-index value (rack, travel and hoist)
and then press the Read button. Current travel and hoist offsets in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
Even if you decide to change only one value, both values must be specified!
The parameter screen on operators panel enables users to save the parameter settings of the crane to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Error! Reference source not found. the number 190617 is entered to represent
19.6.2017. Afterwards the save button can be pressed.
Absolute encoders for hoist are referenced from parameter adjustment screen by pressing corresponding button.
24 Travel motor running too long, +EXT-418M1 Something is blocking the movement. Check for
reasons.
25 Hoist motor running too long, +EXT-416M1 Something is blocking the movement. Check for
reasons.
26 Forks SD motor running too long, +EXT-421M1 Something is blocking the movement. Check for
reasons.
27 Forks DD motor running too long, +EXT-422M1 Something is blocking the movement. Check for
reasons.
28 Communication error with transport system PLC The conveyor PLC is not responding.
(receive direction) - Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
29 Communication error with transport system PLC (send Same as above.
direction)
30 Communication error with MFCS (receive direction) MFCS is not responding.
31 Communication error with MFCS (send direction) MFCS is not responding.
32 Enormous value of absolute encoder or magnet Check absolute encoder value and both magnet
switches - travel switches.
34 Erroneous value of absolute encoder or magnet Check absolute encoder value and both magnet
switches - hoist switches.
40 Automatic start not possible: wrong location Check entered location.
41 Automatic start not possible: crane occupied Pickup is not possible if there is already a pallet
on the crane.
42 Automatic start not possible: crane is empty Drop is not possible if crane is empty.
43 Barcode mismatch MFCS has issued a command for a pallet which
is not on crane.
44 Underweight Check the load, remove it if it is too heavy.
Calibrate the load sensor.
45 Overweight Check the load, remove it if it is too heavy.
Calibrate the load sensor.
46 No clearance between crane and rack 1 Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
47 No clearance between crane and rack 2 Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
48 Material picture differs from sensor The material picture occupancy and the sensor
436B1 state differ.
49 Material movement not successful The crane has performed movement, but the
status of occupancy sensor has not changed.
Check the situation.
50 Transport system conveyor not ready Check if transport system is without alarms and
in automatic mode.
51 MFCS error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
52 Automatic start not possible: fork not in the middle Place both forks manually to middle position
and check both sensors 435B3 and 435B4.
53 Sagging of Axis hoist Hoist brake malfunction, check hoist motor
brake.
54 Crane out of working area (travel) Software limit switch was triggered. Move the
crane back to the working area.
55 Crane out of working area (hoist) Software limit switch was triggered. Move the
crane back to the working area.
GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 137/251
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
56 Crane out of working area (fork SD) Software limit switch was triggered. Move the
crane back to the working area.
57 Crane out of working area (fork DD) Software limit switch was triggered. Move the
crane back to the working area.
60 Deposit to rack not possible - location occupied (side=1, Rack location is occupied, or sensor is not
depth=1) working properly 433B1.
61 Deposit to rack not possible - location occupied (side=1, Rack location is occupied, or sensor is not
depth=2) working properly 434B1.
62 Deposit to rack not possible - location occupied (side=2, Rack location is occupied, or sensor is not
depth=1) working properly 433B2.
63 Deposit to rack not possible - location occupied (side=2, Rack location is occupied, or sensor is not
depth=2) working properly 434B2.
64 Pick from rack not possible - location empty (side=1, Rack location is empty, or sensor is not working
depth=1) properly 433B1.
65 Pick from rack not possible - location empty (side=1, Rack location is empty, or sensor is not working
depth=2) properly 434B1.
66 Pick from rack not possible - location empty (side=2, Rack location is empty, or sensor is not working
depth=1) properly 433B2.
67 Pick from rack not possible - location empty (side=2, Rack location is empty, or sensor is not working
depth=2) properly 434B2.
68 Pick from rack not possible - depth 1 occupied (side=1, Rack location of first depth is occupied, or
depth=2) sensor is not working properly 434B1.
69 Pick from rack not possible - depth 1 occupied (side=2, Rack location of first depth is occupied, or
depth=2) sensor is not working properly 434B2.
71 E-STOP push button, CP101 Release stop button on the cabinet.
72 Door to C101 open Close the door at aisle entry.
73 Light grid - MLG, T10 Check light grid, remove any obstacles and
reset error.
74 Light grid - MLG, T110 Check light grid, remove any obstacles and
reset error.
75 E-STOP push button, CP401 Release stop button on the cabinet.
115 Service M required Maintenance of crane is required. After
maintenance is done, confirmation on
operators panel is needed.
116 Service 3M required Maintenance of crane is required. After
maintenance is done, confirmation on
operators panel is needed.
117 Service 6M required Maintenance of crane is required. After
maintenance is done, confirmation on
operators panel is needed.
118 Service 12M required Maintenance of crane is required. After
maintenance is done, confirmation on
operators panel is needed.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
crane as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a pallet
from the crane, he should delete its material picture on the crane, or, if he has loaded the pallet onto the crane, he
should enter the correct barcode.
Go to the service screen and click on material icon. The screen shown in Figure 5.34 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
If pallet is loaded in the manual mode to crane deck, enter its barcode in the New barcode field and tap
button on the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be
accepted.
If crane deck is empty and you want to delete material picture, enter 0 in the New barcode field to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted (sensor
436B1).
Service and maintenance of the crane is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS system. Crane can still operate although service warning is
present. Service warning can be reset only on operators panel on Service screen by pressing reset for each
service separately.
Reset button can be pressed only if service is done according to scheduled maintenance plan!
Turn the switch +SB1-7Q1 on the main power cabinet to position ON.
Turn the switch +L01-202Q1 on the shuttle main cabinet +L01 to position ON.
Turn the switch +L01-202Q1 on the shuttle main cabinet +L01 to position OFF.
Turn the switch +SB1-7Q1 on the main power cabinet to position OFF.
Safety switches, which limit the shuttles movement area: travelling (208S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the shuttle, he needs to open a door to access the aisle. The faults on the shuttle can be
reset and machine locally operated only when the safety is re-established. To do this, the operator must press the
reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operators panel or when access to aisle is needed to
disable inattentional automatic shuttle movement. When shuttle is in local regime it can operate only in manual or
semi-automatic mode from the panel.
Remote regime is normal operating regime, when machine is controlled remotely by MFCS.
In manual mode, all movements of the machine are made by pressing the respective buttons on the operators panel.
In semi-automatic mode, a machine itself performs a simple operation that consists of a movement to the selected
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
location, loading of a material from that location, or the depositing of material to it. Manual or Semi-automatic mode
can be selected from the operators panel and are enabled only in local regime.
The control regime is signaled on the operators panel and on MFCS PC.
Key on the aisle entrance enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
The local regime is enabled only when the key-locks are set in the following ways:
The remote regime is enabled only when key-locks are set as follows:
When shuttle is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, shuttle will finish current task and then stop. Shuttle will not start
executing next task to allow entrance to shuttle aisle. Always wait to shuttle finishes current task, otherwise automatic
reset could not be possible and manual intervention will be needed. When shuttle is stopped, key can be turned to
LOCAL position.
In all other key positions shuttle is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Switch key to AUTO FINISH on aisle entrance enclosure and wait till shuttle finishes current task.
Led light for operation on aisle entrance enclosure should be off, in case that led light is on or blinking,
operator should wait that shuttle finishes the current task.
When shuttle is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the shuttle cabinet to LOCAL position.
Now the shuttle is in LOCAL regime and after resetting the faults, it can be operated from the operators panel.
Remove a pair of keys from the key-lock on shuttle cabinet; this is only possible when the key-lock is
switched to REMOTE position.
Leave the shuttle and close the aisle door.
Put the pair of keys to the key lock in aisle entrance enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.
5.6.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.38. They represent:
Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttles horizontal
position.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (conveyor) designated with index giving the logical coordinate.
5.6.4.2.1 Buttons
There are six buttons on top of the main screen as shown in Table 5.5. With pressing button operator change screen or
execute an action.
Button Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.6.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.6.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.6.4.3.
Opens the alarm screen on which we display all the alarms, as shown Figure 5.39. If an alarm
is present, the button flashes red.
If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit shuttle parameters.
The first icon represents shuttle regime, on the icon is seen which device can control the shuttle. There are three
different icons of which two are used for displaying the controlling partner, as shown in the Figure 5.40.
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys arent in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operators panel.
Shuttle mode is displayed via assorted buttons background colours as shown in Figure 5.42.
Colour meaning:
5.6.4.3 Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle or red if its safety related.
5.6.4.3.1 Shuttle
5.6.4.4 Mode
If the shuttle is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the shuttle is controlled via the operators panel as explained in the Chapter 5.6.4.2.2, then the operator can set
control mode by clicking the button for local mode, or button for semi-automatic mode.
5.6.4.4.1 Manual
First button activates the manual control of the shuttle. Operator can control shuttle movement from that screen.
Arrows above physical buttons represent the direction of movement.
F1 - Fast speed movement, must be pressed with other action button F1...F7.
F8 - Reset faults.
Incautious manipulation with the shuttle in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the shuttle can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the shuttle
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.6.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
5.6.4.4.2 Semi-automatic
Button activates the semi-automatic mode, where the operator inputs the desired action and location in the input
fields. When the start button is pressed the shuttle starts executing requested task.
Input fields:
6. Command, where the operator selects the desired action from a drop-down list:
a. - - - - which symbolizes no action is selected
b. Move which symbolizes that the shuttle will move to the selected location.
c. Pick - which symbolizes that the shuttle will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the shuttle will move to the selected location and deposit the material
at that location.
7. Travel, were the entered number represents the desired horizontal location conveyor number.
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the shuttle. It is given in terms of four-digit number ssdd with
the following meaning:
o 0: initialization of a command,
o 70 72: conveyor movement,
o 90 95: material movement and other finalization steps.
When switching from the manual to the semi-automatic mode the shuttle is not yet operating automatically, which is
signalized via colour as defined in the Chapter 5.6.4.2.3. To start the automatic operation, the start button must be
pressed. If the operation was successfully finished and regime not changed, then automatic operation can be continued
(is not reset).
Each time the automatic operation is started after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the shuttle stops all actions (automatic operation is lost). After
reset of the faults, the shuttle continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
Offset of the travel must be set in such a way, that conveyor is properly aligned to transport conveyor.
On the offset screen, shown in Figure 5.47, first enter the location in form of one-index value (travel index) and then
press the Read button. Current travel offset in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
The parameter screen on operators panel enables users to save the parameter settings of the shuttle to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Figure 5.48 the number 180617 is entered to represent 18.6.2017. Afterwards the
save button can be pressed.
system.
67 No clearance between shuttle and transporter 211 Remove obstacle and check sensor on transport
system.
68 No clearance between shuttle and transporter 222 Remove obstacle and check sensor on transport
system.
69 No clearance between shuttle and transporter 311 Remove obstacle and check sensor on transport
system.
70 No clearance between shuttle and transporter 21 Remove obstacle and check sensor on transport
system.
71 No clearance between shuttle and conveyors - path not Remove the pallet or material (plastic foil) that was
clear jammed in the gap between the shuttle and
conveyors.
72 E-STOP push button, CP101 Release the stop button on the cabinet.
73 E-STOP push button, CP201 Release the stop button on the cabinet.
74 E-STOP push button, CP301 Release the stop button on the cabinet.
75 E-STOP push button, CP401 Release the stop button on the cabinet.
79 Door to shuttle open Close door.
80 Door to C101 open Close door.
81 Door to C201 open Close door.
82 Door to C301 open Close door.
83 Light grid - MLG, T10 Check light grid, remove any obstacles and reset
error.
84 Light grid - MLG, T110 Check light grid, remove any obstacles and reset
error.
85 Light grid - MLG, T21 Check light grid, remove any obstacles and reset
error.
90 Barcode mismatch: deck MFCS has issued a command for a pallet which is not
on crane.
91 MFCS: unknown error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit operation
on conveyors.
92 MFCS: synchronization failure MFCS has requested the crane to raise an error.
115 Service M required Maintenance of crane is required. After maintenance
is done, confirmation on operators panel is needed.
116 Service 3M required Maintenance of crane is required. After maintenance
is done, confirmation on operators panel is needed.
117 Service 6M required Maintenance of crane is required. After maintenance
is done, confirmation on operators panel is needed.
118 Service 12M required Maintenance of crane is required. After maintenance
is done, confirmation on operators panel is needed.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
shuttle as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a
pallet from the shuttle, he should delete its material picture on the shuttle, or, if he has loaded the pallet onto the
shuttle, he should enter the correct barcode.
Go to the service screen and click on material icon. The screen shown in Figure 5.50 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
If pallet is loaded in the manual mode to shuttle deck, enter its barcode in the New field and tap button on
the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be accepted.
If shuttle deck is empty and you want to delete material picture, enter 0 in the New field to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted.
Service and maintenance of the shuttle is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS. Shuttle can still operate although service warning is
present. Service warning can be reset only on operators panel on Service screen by pressing reset for each
service separately.
Reset button can be pressed only if service is done according to scheduled maintenance plan!
Turn the switch +SB1-8Q1 on the main power cabinet to position ON.
Turn the switch +L01-302Q1 on the shuttle main cabinet +L01 to position ON.
Turn the switch +L01-302Q1 on the shuttle main cabinet +L01 to position OFF.
Turn the switch +SB1-8Q1 on the main power cabinet to position OFF.
Safety switches, which limit the shuttles movement area: travelling (308S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the shuttle, he needs to open a door to access the aisle. The faults on the shuttle can be
reset and machine locally operated only when the safety is re-established. To do this, the operator must press the
reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operators panel or when access to aisle is needed to
disable inattentional automatic shuttle movement. When shuttle is in local regime it can operate only in manual or
semi-automatic mode from the panel.
Remote regime is normal operating regime, when machine is controlled remotely by MFCS.
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
In manual mode, all movements of the machine are made by pressing the respective buttons on the operators panel.
In semi-automatic mode, a machine itself performs a simple operation that consists of a movement to the selected
location, loading of a material from that location, or the depositing of material to it. Manual or Semi-automatic mode
can be selected from the operators panel and are enabled only in local regime.
The control regime is signaled on the operators panel and on MFCS PC.
Key on the aisle entrance enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
The local regime is enabled only when the key-locks are set in the following ways:
The remote regime is enabled only when key-locks are set as follows:
When shuttle is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, shuttle will finish current task and then stop. Shuttle will not start
executing next task to allow entrance to shuttle aisle. Always wait to shuttle finishes current task, otherwise automatic
reset could not be possible and manual intervention will be needed. When shuttle is stopped, key can be turned to
LOCAL position.
In all other key positions shuttle is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Switch key to AUTO FINISH on aisle entrance enclosure and wait till shuttle finishes current task.
Led light for operation on aisle entrance enclosure should be off, in case that led light is on or blinking,
operator should wait that shuttle finishes the current task.
When shuttle is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the shuttle cabinet to LOCAL position.
Now the shuttle is in LOCAL regime and after resetting the faults, it can be operated from the operators panel.
Remove a pair of keys from the key-lock on shuttle cabinet; this is only possible when the key-lock is
switched to REMOTE position.
Leave the shuttle and close the aisle door.
Put the pair of keys to the key lock in aisle entrance enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.
5.7.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.54. They represent:
Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttles horizontal
position and inclination position for both decks.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (slot in a rack, conveyor) designated with two indices giving the logical coordinate
5.7.4.2.1 Buttons
There are six buttons on top of the main screen as shown in Table 5.6. With pressing button operator change screen or
execute an action.
Button Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.7.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.7.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.7.4.3
Opens the alarm screen on which we display all the alarms, as shown Figure 5.55. If an alarm
is present, the button flashes red.
If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit shuttle parameters.
The first icon represents shuttle regime, on the icon is seen which device can control the shuttle. There are three
different icons of which two are used for displaying the controlling partner, as shown in the Figure 5.56.
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys arent in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operators panel.
Shuttle mode is displayed via assorted buttons background colours as shown in Figure 5.58.
Colour meaning:
5.7.4.3 Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle or red if its safety related.
5.7.4.3.1 Shuttle
5.7.4.4 Mode
If the shuttle is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the shuttle is controlled via the operators panel as explained in the Chapter 5.7.4.2.2, then the operator can set
control mode by clicking the button for local mode, or button for semi-automatic mode.
5.7.4.4.1 Manual
First button activates the manual control of the shuttle. Operator can control shuttle movement from that screen.
Arrows above physical buttons represent the direction of movement.
F1 - Fast speed movement, must be pressed with other action button F1...F7.
F8 - Reset faults.
With button above keys F4 to F7 Deck 501/502 you select which deck is controlled.
Incautious manipulation with the shuttle in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the shuttle can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the shuttle
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.7.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
5.7.4.4.2 Semi-automatic
Button activates the semi-automatic mode, where the operator inputs the desired action and location in the input
fields. When the start button is pressed the shuttle starts executing requested task.
Input fields:
8. Command, where the operator selects the desired action from a drop-down list. There are three options for
each deck:
a. - - - - which symbolizes no action is selected
b. Move which symbolizes that the shuttle will move to the selected location.
c. Pick - which symbolizes that the shuttle will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the shuttle will move to the selected location and deposit the material
at that location.
9. Rack, were the entered 52 for dynamic rack or 0 for conveyors.
10. Travel, were the entered number represents the desired horizontal location in dynamic rack or index in
dynamic rack construction.
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
Shuttle can drop in rack construction simultaneously if rack slots are close to each other.
Start button.
Cancel button.
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the shuttle. It is given in terms of six-digit numbers with the
following meaning ssd1d1d2d2.
o 0: initialization of a command,
o 60 61: inclination movement down,
o 70 72: conveyor movement,
o 80 81: inclination movement horizontal position,
o 90 95: material movement and other finalization steps.
When switching from the manual to the semi-automatic mode the shuttle is not yet operating automatically, which is
signalized via colour as defined in the Chapter 5.7.4.2.3. To start the automatic operation, the start button must be
pressed. If the operation was successfully finished and regime not changed, then automatic operation can be continued
(is not reset).
Each time the automatic operation is started after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the shuttle stops all actions (automatic operation is lost). After
reset of the faults, the shuttle continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
Offset of the travel must be set in such a way, that conveyor is properly aligned to rack construction or transport
conveyor.
On the offset screen, shown in Figure 5.63, first enter the location in form of two-index value (rack and travel index)
and then press the Read button. Current travel offset in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
The parameter screen on operators panel enables users to save the parameter settings of the shuttle to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Figure 5.64 the number 190617 is entered to represent 19.6.2017. Afterwards the
save button can be pressed.
65 No clearance between shuttle and T024 Remove obstacle and check sensor on transport
system.
66 No clearance between shuttle and T321 Remove obstacle and check sensor on transport
system.
67 No clearance between shuttle and T322 Remove obstacle and check sensor on transport
system.
68 No clearance between shuttle and rack 52, place X = Remove obstacle and check sensor on transport
1..5 system.
69 No clearance between shuttle and rack 52, place X = Remove obstacle and check sensor on transport
6..12 system.
70 No clearance between shuttle and rack 52, place X = Remove obstacle and check sensor on transport
13..19 system.
71 No clearance between shuttle and rack 52, place X = Remove obstacle and check sensor on transport
20..24 system.
111 Barcode mismatch: deck C501 MFCS has issued a command for a pallet which is
not on crane.
112 Barcode mismatch: deck C502 MFCS has issued a command for a pallet which is
not on crane.
113 MFCS: unknown error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
114 MFCS: synchronization failure MFCS has requested the crane to raise an error.
115 Service M required Maintenance of crane is required. After
maintenance is done, confirmation on operators
panel is needed.
116 Service 3M required Maintenance of crane is required. After
maintenance is done, confirmation on operators
panel is needed.
117 Service 6M required Maintenance of crane is required. After
maintenance is done, confirmation on operators
panel is needed.
118 Service 12M required Maintenance of crane is required. After
maintenance is done, confirmation on operators
panel is needed.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
shuttle as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a
pallet from the shuttle, he should delete its material picture on the shuttle, or, if he has loaded the pallet onto the
shuttle, he should enter the correct barcode.
Go to the service screen and click on material icon. The screen shown in Figure 5.66 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
If pallet is loaded in the manual mode to shuttle deck, enter its barcode in the New field and tap button on
the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be accepted.
If shuttle deck is empty and you want to delete material picture, enter 0 in the New field to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted.
Service and maintenance of the shuttle is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS. Shuttle can still operate although service warning is
present. Service warning can be reset only on operators panel on Service screen by pressing reset for each
service separately.
Reset button can be pressed only if service is done according to scheduled maintenance plan!
Basic unit of I2MFCS system is a transport unit (usually a pallet). I2MFCS does not care about the loading unit stored on
a transport unit.
In normal operation, I2MFCS gets orders or complex commands for transport of transport units from superior system.
Based on the system setup it tries to find the optimal way to move the transport unit from source to destination. To do
so, it must break a complex commands to a number of simple commands, and send them to adequate transport
devices in proper sequence. Transport devices try to perform the requested movements and reply to I2MFCS
accordingly. Based on the response from transport devices I2MFCS promptly informs superior system about command
execution.
In case of superior system malfunction or some special requirement, the system enables manual typing of complex as
well as simple commands.
All the above process is promptly visualized on the user interface in terms of tables and graphics. Real-time visualization
enables an operator to easily monitor the system and react appropriately in case of a need.
In event of system malfunction, a problematic device is highlighted and the reason for the malfunction is displayed as a
text message to allow an operator for quickly intervention with appropriate corrective measures.
6.1 Architecture
The software has modular architecture and is designed using modern concepts. As presented in Error! Reference
source not found., it consists of:
Database, to store all important information like commands, positions of transport units, configuration of
devices and locations,
Telegrams module for communicating with PLCs via TCPIP telegrams,
Core application, which includes all business logic, and
User interface module through which a user can interact with the system.
6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
UI
PLC
Telegram UI
PLC
PLC
PLC
PLC
Figure 6.1 I2MFCS system architecture
6.1.1 Database
Microsoft SQL Express or Microsoft SQL server system can be used for manipulation of tables and records in a database.
The configuration of the database is performed during the commissioning by running SQL script.
Based on the current system state, it selects commands and coordinates its execution among transport devices like
conveyors, shuttle-cars, and stacker-cranes. From the received feedback it refreshes representation of the system in
the internal memory, database, and reports statuses to the superior system.
6.1.4 UI module
User interface module or UI module allows a user to monitor and control the warehouse system. It offers simple and
intuitive user interface, which allows for efficient operation of the warehouse. From UI module, a user can monitor and
control the behavior of the whole warehouse system.
At any time a user can check the real-time visualization od system with shown positions of transport devices,
transport units, crucial sensors, and all other vital information.
UI module provides visual and textual alarm messaging to enable a user for quick response-
From UI module it is also possible to change the behavior of the system, enter new commands or change their
priority.
A user can check the position of a transport unit in the warehouse.
UI enables user to reconfigure the availability of slots in the warehouse.
A user can browse a database for past events.
User interface module runs as a stand-alone Windows desktop application. It is possible to run many client applications
simultaneously, which connect to the Core service installed on any machine in the network. A client application gets the
current data directly from the core module or from the database.
To exit the UI module, an operator has to press cross in the top right corner (Figure 6.3).
6.2.2 Layout
Main screen in Figure 6.4 consists of main area, surrounded by the control panel on top, the status line at the bottom,
and the application menu on left side.
MFCS/WMS tile is used to change the mode of operation. When MFCS is selected and written inside the tile, only
manually entered commands are sent to execution. When WMS is selected, only commands received from WMS are
send to execution.
The semaphore above the tile shows weather the tile is active (green) or inactive (gray). Command are executed only
when the tile is active. Tile becomes inactive in case of some critical errors, or when user manually changes its state.
To change the mode, operator has to right-click the tile and from the context menu (Figure 6.5) select:
When a user does not have enough permissions, some context menu items may be inactive.
A device tile can represent one (vehicles) or many devices (conveyors). From the tile, we can observe device status and
perform some basic control.
From the device context menu (Figure 6.6) one can select:
When a fault occurs device goes to alarm state (red). When fault is reset, or when a device mode of operation changes
from local to remote, device goes to remote automatic inactive mode (yellow). By selecting Auto on, device goes to
remote automatic active mode, where it is able to fetch and execute commands.
When a user does not have enough permissions, some context menu items may be inactive.
When a user does not have enough permissions, some application menu items may be inactive.
In next sections, application menu screens will be presented in detail in order of their appearance.
A segment or a vehicle is surrounded by a box, which changes its color according to its state. The box moves around a
display to make the visualization more realistic.
A segment or a vehicle box includes individual decks, displayed as rounded gray squares. Each deck has a nametag,
which corresponds to the mechanical drawings. Small circles outside the top left corner of the square represent some
vital sensors:
When a deck is occupied with a transport unit, the square becomes black with a wider border and has transport unit ID
written inside, like in place T002 in Figure 6.7.
A box, representing conveyor system segment (a group of conveyors) or vehicle (shuttle or crane), is changes its color
according to the status of a segment/vehicle. The color-coding is the same as for tiles in the control panel:
A user can control a device through a context menu, which appears after right-click on a device (Figure 6.8).
By hovering a mouse pointer over a device some additional information is pop-up. The contents differs from device to
device. Example in Figure 6.9 shows a device mode, currently performed operation (state machine), positions given in
terms of rack locations (logical) and in millimeters (physical). For each deck it also displays transport unit on it (TU), and
a task it executes (execute) and a task which is about to execute (buffer). It also shows some vital sensor information.
By pressing the reset button on the right of the table, request to acknowledge alarms is sent to all devices in the
system. Successfully acknowledged alarms are then removed from the screen.
6.2.5.1 Tables
6.2.5.1.1 Description
WMS ID: has a value greater than 0, if a command was received from WMS, and 0, if command was issued
from MFCS,
MFCS ID: each command gets its unique MFCS ID.
Task: explains the purpose of a command. It can be
o Material commands (create, move, delete),
o Segment commands (reset, auto on, auto off),
o Other commands (cancel of an existing command),
GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 184/251
6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
TU: shows information about transport unit involved in a command (for material commands),
Source: position of a transport unit before command start (form material commands),
Target: target position of a transport unit at command completion (for material commands),
Segment: conveyor segment or vehicle name (for segment commands),
Cancel: MFCS ID of a command to be canceled (for job commands),
Priority: commands with higher number will be executed earlier,
Info: some text description of a command,
Status: shows the status of a command. It can be:
o Not active when a command is waiting for execution,
o Active when a command is in execution,
o Finished when a command is completed, and
o Canceled when WMS or a user has canceled it.
Time: a time when a command entered a system.
On Detailed simple commands screen one can observe how the selected complex command splits to a number of
simple commands. All simple commands share common MFCS ID, but have different IDs. This IDs can be also observed
in Visualization screen. Task column displays a simple command in descriptive way. Status can be:
When a user selects a command, its details display on the control desk.
By clicking on a column header, command sort ascending or descending with respect to the information stored in this
column.
Many command headers possess a filter icon. By clicking on it, an input field appears to which a user can enter a text
required in displayed records. In Error! Reference source not found. text W:11 was entered to Target column to display
only commands, which have target location in rack W:11.
6.2.5.2.1 Refresh
Majority of tables in the application are not refreshed automatically. A user has to press the refresh button to update
the screen with latest values of database records.
6.2.5.2.2 CMD TU
By pressing CMD TU button, a user can enter a command, which involves transport unit operation. The command can
be:
When entering a command (Figure 6.13), the user interface helps user to fill the fields. If something is wrong or missing,
a warning is displayed. Some fields are interconnected, for example TU designation and source location. If user enters
source location, he can press small B button, and application will automatically fill in the transport unit ID. Similarly, by
pressing L button, source location is filled-in based on the entered transport unit information. When all fields are
correctly filled-up, the user should press the confirm button, to send the command to execution. Anytime during he can
also change his mind and cancel the operation.
By pressing CMD Segment button, a user can enter a command, which involves operation on conveyor segments or
vehicles. He can select among commands:
For segment information, a user can enter exact segment designation, for example T00, T01, or vehicle name, for
example C1, C2. To address all segment at once, he can use an asterisk symbol (*).
To restart or delete an existing command, a user must first select it. The command in question displays on control desk.
Now he can request to restart it, or delete it by pressing the corresponding button. To confirm the operation, an
operator must press Confirm button.
Additionally, in case of deletion, an operator must specify the reason, which can be:
It is important to enter the correct reason; otherwise, the system can retry the same command again and again.
From the control desk, a user can delete the selected transport unit, or create a new one on desired location. By using
move command, a transport unit can be booked to another location by issuing corresponding delete and create
command.
With the move command, the transport unit does not change its physical location; it only updates its location in the
database.
Execute commands or
Execute simple commands only.
In normal operation, the new tile displays Commands. In this mode the Simple command table shows current status of
simple commands.
When an operator wants to operate the devices by issuing simple commands, he must first change the mode of
operation in control panel to MFCS (left tile) and to Simple commands (the new tile). Now the execution of simple
commands, which MFCS generates from complex commands, stops.
Figure 6.16 Simple commands screen with new tile in control panel
Move: to move a transport unit from source to target location; both locations are on conveyor system,
Create: to create a transport unit on desired source location,
Delete: to delete a transport unit from desired location,
On one hand an inactive command can be repeated by selecting Restart button. On the other hand, a command can be
canceled by selecting Delete button. Each operation must be Confirmed before it goes to execution.
Time stamp,
Severity description (Event, warning, error, exception),
Type (module that logged the information), and
Description in plain English only.
Alarms screen hold information of all alarms that appeared in the past,
Movements screen gives detailed information about transport unit movement in the warehouse,
Commands screen lists all complex commands,
Simple commands screen lists all simple commands, and
Events screen presents all events that appeared in the past.
Each history screen includes simple filter above the table as for example Movements screen in Figure 6.18. User must
enter start and end date to display a time interval of his interest. On some screens, it is also possible to put filter on
some other columns. For example, in Movements screen one can select specific location and observe the flow of
transport units over it, or give a transport unit data, to check its movements in the warehouse.
The filter is applied when user presses the Refresh button. For records present in table, a user can use sorting and
additional filtering from column headers.
changing user,
changing the application language, and
managing the database.
By entering the right user and password, another user can be logged in the system. User logging is mainly used to
elevate permission level to use some advanced functions of the system. When elevated permission are not needed
anymore, the user should be logged out.
Additional users with password and desired permission levels can be entered directly into the database.
The database can be compacted manually by using SQL commands directly by Microsoft SQL server tools, or
automatically by pressing Reduce database button. The latter, deletes the least important records to get additional 1
GB of space.
Before compacting, make complete backup of the database. This operation is only allowed for IT specialists!
7.1.1.1.1 Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.
7.1.1.1.2 Maintenance
Driving station
2 1
4 3
Other parts
1 2 3 4
Lubrication scheme
7.1.1.2.1 Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.
7.1.1.2.2 Maintenance
Lubrication scheme
7.1.1.3.1 Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
General inspection
In case that some serious maintenance of the equipment was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.
7.1.1.3.2 Maintenance
Lubrication scheme
7.1.1.4.1 Inspection
Daily inspection
Make visual control that the lines of conveying the pallet of chainand roller conveyor are perpendicural. Also check that
pallet is not inclined during lifting.
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.
7.1.1.4.2 Maintenance
Lifting device
1 4 6 3 5
2 7
Lubrication scheme
3 1 2
7.1.1.5 Stopper
7.1.1.5.1 Inspection
Daily inspection
Make visual control that the lines of conveying the pallet of chainand roller conveyor are perpendicural. Also check
paralelity of the stopper.
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.
7.1.1.5.2 Maintenance
Lubrication scheme
7.1.1.6.1 Maintenance
Weight control
Driving set
Tilting table
2 1 3
Figure 7.15 Maintanance parts of the tilting table
Other elements
1 2
Lubrication scheme
2 3
1
Driving set
Other elements
1 2
Lubrication scheme
2 3
7.1.4 Crane
ATTENTION Before any interference on the lifting unit, put the lifting carriage onto shock absorbers
situated on the bottom carrier.
Driving unit
ATTENTION Before replacing the running wheel, bearings, the ride gear, or the free drive wheel set, lift the
framework of the crane for approximately 5mm by using an auxiliary lifting device. This
unloads the wheel set and enables unscrewing and replacement or elimination of faults.
Lifting carriage
Guiding wheels of the lifting carriage have to be replaced in case of damaged bearings or when it becomes impossible
to eliminate the air slot by adjusting screws. After replacement of wheels, readjust the air slot.
For servicing the lifting carriage (in case when works have to be done from the lower side of the lifting carriage), two
supporting pillars must be provided. Lowering the lifting carriage on the pillars prevents uncontrolled descending of the
carriage.
0,3<air slot<1,2
20 Two row cylinder damage Replace bearing
bearing 3.000 wear
- lubricate Lubricate with Aralub
SKA or Multitop
21 Leading wheel damage Leading wheel
1.200 wearing out change
travel ease
noise at run Lubricate
22 Locking device 4.600 fixing Clamp set
tightening momentum replace
22 22
20 20
6 6
19
6
Figure 7.22 Lifting carriage
11 9
10
16
19
21
18
19
20
27
28
20
3
27
17
28
22
11
Lubricants:
According to DIN 15020, the steel ropes of the lifting unit must be regularly maintained, where the maintenance
procedure depends on the type of the lifting device, its use and the type of rope .
Built-in DIEPA steel rope is soaked with a special highly resistant lubricant and anti-corrosion protective material. If dry
areas appear on the rope surface due to any reason the rope must be obligatory lubricated. Regular lubrication has a
very positive influence on life span of the rope.
Most frequently, the rope is lubricated with a brush or with a rag. When lubricated with a rag, the use of protective
gloves is obligatory.
ATTENTION Almost all suitable oils and lubricants are allowed for lubricating the steel rope.
Lubricants almost do not penetrate in the interior of the rope therefore avoid excessive
lubrication. Excessive lubricant remains on the outer side of the rope and makes recognition of
damages and signs of wear difficult.
If damaged wires that could damage adjacent ropes at rope transition over the rope wheels are detected at inspection,
such damaged ends of wires have to be removed immediately. Never cut them off with pliers.
The best way of remediation is to bend such wire in different directions until the wire breaks somewhere near the rope.
Such parts of the rope must be marked and inspected in shorter time intervals.
During operation, the rope is exposed to permanent wearing. Therefore, it should be inspected in regular time
intervals.
A number of visible damages of the wires can disclose the wear level of ropes and the time when a rope needs to be
replaced. The rope must be inspected (possibly in the area of biggest folding) on two different distances.
Number of damaged wires in outer braided wires, and time when the replacement of rope is necessary, depends on
rope construction and class of the device operation.
Steel rope:
Operational class: 4m
10
11
7.1.4.9 Ladder
12
11
10
8 9
19
1. First condition for reliable operation of the stacker crane is careful execution of all prescribed inspections,
professional lubrication and maintenance.
2. A register with all characteristic data about the crane is enclosed to the instructions. The investor arranges
control book for maintenance and lubrication of the crane. Both books must be on the crane, or in the
technical department, or in workshop.
3. Before the lubrication and maintenance (or any other work on the crane), conditions, cited in suitable
directions for safe use of stacker cranes, must be fulfilled. Lubrication should be done in accordance with the
lubrication scheme, where theoretical terms are given. Individual parts must be lubricated more frequently
according to the opinion of the responsible maintainer at regular examinations. Every regular or extraordinary
lubrication need to be recorded in the control book.
4. Use only prescribed or equivalent lubricants, namely:
Oil INA EPOL 310, FAM REDOL 8610
Oil INA POLAR K 68, SHELL OMALA 220
Consistent grease FOR LPD or INA LIS-3
WIPPERMANN WKS-Special
NOTE:
Manufacturers instructions must be strictly followed during the maintenance and lubrication of the reduction gears
and electrical motors! At lubrication of the catching device, braking surfaces must remain dry.
5
1
2
2
ATTENTION The control sheet is intended for machine inspections. For the user inspections, described in
the table, are obligatory. See manufacturer's equipment documentation enclosed to the
instructions for use (appendix, item 16).
INFORMATION In the beginning of the year, a term plan of maintenance needs to be made. It is necessary to
lead a diary of maintenance works for all interventions and maintenance works.
For regular maintenance of the system, electro-maintainer is needed. Maintainer must have required professional
electrical education for maintenance and servicing of automatic devices.
Maintainer must:
Have complete electrical documentation of the warehouse and all necessary tools for electrical maintenance
Be acquainted in details with the system
Be acquainted with all operating modes
Be acquainted with all safety systems in the warehouse
DANGER In case that units which require parameter setting or software changes are replaced, this must
be performed by a qualified person!
The current collectors must be checked every two months or in accordance with operational requirements.
7.2.2 Grouding
All joints of the metallic construction with grounding of the building must be examined. We also recommend an annual
inspection of the operation of safety devices for electrical shock protection.
Use a clean and soft rag to remove dust from the optics cover.
Wipe the window for light output on the optics cover with a clean and damp cloth.
Check fixation of sensors, condition of connectors and other connections in the connection cabinets and in the main
cabinet.
ATTENTION Do not use aggressive cleaning agents. Do not use abrasive cleaning agents.
3 1 Axis 1 600.0000.0000-02-02 GP
4 1 Axis 2 600.0000.0000-05-01 GP
4 1 Arm 1 1157.700.01.02.002
5 1 Arm 2 1157.700.01.02.003
6 1 Arm 3 1157.700.01.02.004
7 1 Arm 4 1157.700.01.02.005
10 1 Housing unit with bearing PASEY 40-N INA
17 1 Chain 12 B-1 DIN 8187; 12-B1; li.+1 con. li. Typ 3 Wippermann
8.1.1.5 Stopper
Pos. Number Name Plan, standard Manufacturer
3 Flag 1157.100.10.04.005
8 2 Brush PP 90 MINK
8.1.4 Crane
8.1.4.1 Table of crane spare parts
Complete EUROFORK spare part list (priority B and C) is available as a separate document (TR030S8039a.pdf) which is
part of the forks documentation.
8.2.2 Crane
8.2.2.1 Wearing parts
Poz. Number Description Type Manufacturer