Скачать или смотреть Vertical Heart, Horizontal Lifelines — An On-Site Chronicle of Changheng’s Automated Storage System

Walk into the 21‑metre‑high, nearly 100‑metre‑long automated warehouse and you are greeted by steel aisles and LED ribbons that carve a “metal canyon” in mid‑air. Temperature and humidity sensors keep the interior at a constant 23 °C, while grey pallets glint like the ticks of a precision gauge. On only 3 500 m² of floor area, the structure houses 9 000 standard 1 200 × 1 200 mm pallets, boosting spatial utilisation by more than 60 %.

The vertical core consists of three twin‑mast stacker cranes. Each races horizontally at 2 m/s and lifts at 1 m/s, with a telescopic fork rated for 1 000 kg. Photo‑electric beams, shock‑absorbing buffers and magnetic encoders limit sway and position error to ±2 mm, so a full in‑out cycle takes barely 70 s.

The horizontal “blood vessels” are shared by AGVs and an under‑floor RGV. Laser‑guided SLAM AGVs cruise at 1 m/s; hot‑swap Li‑ion packs keep downtime below two minutes per shift. The RGV accelerates at 0.6 m/s², shuttling two pallets at once and docking seamlessly with the stacker cranes. A WCS orchestrates “alternating cover”: AGVs handle long‑haul moves, the RGV manages cross‑aisle transfers, ensuring a free path at all times.

Chain‑drive roller conveyors form the intake spine. Powered by 24‑V zone drives, they keep peak noise under 65 dB. Integrated scan/weight/dimension modules work with RFID tags to track every pallet’s route, dwell time and temperature history. If an anomaly appears, a bypass lifter diverts the pallet in under five seconds. All nodes run on redundant PLCs linked by an EtherCAT bus, keeping multi‑machine latency below 50 ms.

At full load the system processes up to 650 pallets per hour, while annual unplanned downtime stays under 1 %. Compared with a conventional flat warehouse, the installation saves 80 % labour, cuts energy use by 35 %, and more than halves land costs. When night falls, blue laser beams from the AGVs sketch geometric lines on the floor and yellow crane masts glide up and down the canyon. Green LEDs on the dashboard rise steadily, showing live throughput—proof that this is not just a warehouse, but a powerful heart pumping the lifeblood of tomorrow’s smart supply chain.
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