Small Item Storage: Mechanised Systems (Vertical and Horizontal Carousels)

Vertical Carousel

This is an automated vertical storage device which saves valuable floor space. The vertical construction of carousel can go up to a maximum height of 7 m. The storage shelves are arranged in two rows and are held in special carriers. These are suspended at each end in heavy duty roller chains. The shelves can be designed to carry any type, size and quantity of items. For small items, plastic bins of suitable are used.

The movement of the vertical train of shelves is effected by an electro-mechanical device at the heart of which is a micro-processor based logic circuit. At the press of the particular button, the required shelf traverses the shortest path (either up or down) and stops before a window in front of which is a working table. The operator picks up the item easily. Thus the operator does not have to walk around looking for the desired item. The storage and retrieval operation becomes error-free and fatigue-free. As a further step for automation, the carousel can be interfaced with a computer thus making available additional information like stock position, etc., at the touch of a button.

The advantages of Vertical Carousels are:

• Uses a fraction of floor space used by static shelving, usually around 80 sq ft or around 25% of what static shelving would use;
• Simplicity (high reliability, low requirement for electronic coordination of moving parts);
• High speed in picking multiple parts (machine presents all parts in all order requests in one rotation) - when multiple machines are used in conjunction with software, parts can be picked by one person up to 5 times faster than they could be picked from static shelving by that person;
• High weight capacity - up to around 1500 lbs per carrier;
• Flexibility using different configurations of additional shelves in each carrier and reconfiguring when needed;
• Security (when the door at the workstation is locked, the machine is a sealed box); and
• Better ergonomics (all parts are presented at waist level, minimising back problems).

Horizontal Carousels

In Horizontal Carousels, shelved storage 'baskets' are suspended from a continuous overhead chain, which is driven forward or backwards to bring the required stock to the operator. The horizontal carousel is best used when the customer has low ceilings, light parts, or a distribution operation. When multiple machines are placed in a single group to be operated by one individual, that individual can pick from those machines with very little walking. In a group of 4 machines, there is only 12 ft between the pick faces of all 4 machines (as shown below).

The advantages of Horizontal Carousels:

• Ability to be installed under low ceilings;
• Uses between 40 and 60% of the floor space required by a static shelving system;
• Simplicity (high reliability, low requirement for electronic coordination of moving parts);
• High speed in picking multiple parts (machine presents all parts in all order requests in one rotation). When multiple machines are used in conjunction with software, parts can be picked by one person up to 5 times faster then they could be picked from static shelving by that person;
• High weight capacity - up to around 2500 lbs per wire bin;
• Flexibility using different configurations of additional shelves in each bin; and
• Ergonomics (using software "Golden Zones" the faster moving parts are presented at waist level, minimising back problems).