Automotive Parts AS/RS: High-Bay Pallet Selection and Stability Optimization

Background

The customer is a Tier-1 automotive parts manufacturer in North China operating a 24-meter AS/RS. The system processes roughly 1,800 inbound and 1,500 outbound pallets per day using stacker cranes and AGVs. Loads consist of metal totes, with single-pallet weights of 700–900 kg.

Challenges

1. Insufficient racking-load capacity on standard pallets led to excessive mid-span deflection.
2. AGV stability issues caused by low base rigidity and minor pallet rocking.
3. Tight dimensional tolerance required for AS/RS alignment and error-free handling.

Solution

1. Reinforced pallet design

• 1200×1000 mm 3-runner pallets with three steel reinforcements.
• One-piece injection-molded high-stiffness material with controlled tolerances.
• Strengthened fork-entry geometry for stable stacker-crane handling.

2. Racking-load and beam spacing matching

• Calculated racking load using 1000 mm beam spacing as baseline.
• Target racking load: 1000 kg with a 1.2 safety factor.
• Optimized load distribution to prevent off-center placement.

3. AGV compatibility tuning

• Bottom flatness controlled within ±2 mm.
• Added guide blocks at AGV transfer points for consistent fork angles.
• Introduced incoming QC standards to maintain batch consistency.

Results (first 3 months)

• 60% reduction in stacker-crane alarms due to improved pallet stability.
• ~10% faster picking and replenishment cycles from smoother AGV travel.
• Beam deflection kept within specification, eliminating previous over-limit incidents.
• Batch consistency stabilized and handling errors were largely eliminated.

Lessons for peers

1. In high-bay systems, racking load is the key metric, not just dynamic load.
2. AS/RS and AGV operations demand tight tolerances—control flatness and consistency at the pallet level.
3. Load placement matters; off-center loads amplify deflection and alarms.

For high-bay projects, early pallet selection and load validation significantly reduce operational risk and long-term maintenance cost.