Regalbediengerät

What is an automated storage and retrieval system?

An automated storage and retrieval system (AS/RS) is a rail-guided, automated machine that picks up, transports, and stores or retrieves loads within an aisle of a high-bay warehouse or automated storage facility. The travel path runs along a floor-level rail and an overhead guide rail, enabling the machine to approach every storage location in the aisle with precision and repeatability. Depending on the goods being stored, load-handling attachments include telescopic forks for pallets, telescopic platforms for containers, or specialized attachments for long goods.

How does an AS/RS work in practice?

The AS/RS receives travel orders from the higher-level material flow control system or the warehouse management system. It travels horizontally (along the aisle) and vertically (via the lifting mechanism) simultaneously to minimize travel time — a process known as simultaneous or diagonal travel. At the target storage location, the load-handling attachment picks up the goods and retracts them onto the mast, or deposits them into the location. Modern machines use frequency inverters and regenerative braking during deceleration, reducing overall energy consumption.

The control system continuously monitors position, load, and system status. Faults are reported immediately, ideally before a standstill occurs. Depending on the system design, an AS/RS serves exclusively one aisle (single-aisle principle) or, in rare architectures, can switch between aisles via transfer cars, which increases flexibility but also system complexity.

What matters when selecting and planning an AS/RS?

Several factors are critical when designing an AS/RS:

• Throughput per aisle: The required number of storage and retrieval operations per hour largely determines how many aisles and machines need to be planned. Manufacturer specifications for cycle rates are based on standardized cycle definitions (e.g., FEM 9.851), which should be validated against the actual mix of storage locations.
• Load-handling attachments and load carriers: Pallets, containers, and trays require different attachments and affect grid dimensions as well as the machine's weight class.
• Redundancy and availability: A failure of the sole AS/RS in an aisle brings that area to a complete standstill. Maintenance concepts, spare parts availability, and service level agreements with the vendor are therefore part of the investment decision.
• Power supply and energy recovery: With rising energy costs, regenerative drives and load management are becoming increasingly important — however, the extent of these savings depends on the vendor and the load profile.
• Interfaces: Integration into the WMS, material flow computer, and ERP must be contractually defined, including responsibility for interfaces during updates.

When retrofitting existing systems, it must be verified whether new machines are mechanically and control-technically compatible with the existing steel structure and IT infrastructure. This is vendor-specific and should not be taken for granted.