Storage Retrieval System
A valued Smock customer required a storage retrieval
system to feed their machine that could store various sizes and
quantities of sheet metal blanks in order to free up valuable floor
space, provide inventory control and reduce handling cost.
In working closely with the customer, our sales
engineers and designers developed the concept that would fit the
customer needs and a quote to the customer followed.
The resulting system required a load/unload station, a
pick and place system, a storage rack and pallets, a machine load
station, safety fencing and controls to tie it
Our in-house design engineers designed and detailed
the required components while working with the customer to insure they
got a solution that would meet their needs.
After the design was completed and final approval was
granted, the fabrication and vendor sourcing proceeded. We worked
closely with our vendors to meet the timeline and quoted price to the
Our experienced staff of shop personnel began to
fabricating some of the components in our 15,000 sq. ft. shop area. As
vendor supplied items began coming in, our shop personnel began to
assemble the system.
At various stages of completion, we tested the system
to insure it met all the requirement of the customer order and any
additional changes that would create value and safety for the customer.
The customer provided us with the machine our system
was to feed and we integrated it with the system we were supplying at
our facility on our shop floor. After additional tests, the customer
was invited for runoff. We worked with the customer and their
manufacturing personnel to insure they not only got what they ordered
but what they needed. During the runoff, the customer manufactured a
small batch of parts as a test and to provide prototypes for their new
product line. Additionally, we provided hands-on training to the
customers manufacturing personnel on the operation of the system.
After the final runoff and few minor controls changes,
we carefully packed the system to insure that it arrived at the
customers facility in good condition. With our engineering
manager overseeing onsite installation, our in-house personnel
installed the completed system with attention to detail and safety.
After installation and a period of on operation, the
customer determined that additional control system changes were needed
due to changes in their product requirements. Our controls staff took
the customers needs and translated them into PLC program changes that
helped the customer become even more efficient. At Smock we make every
effort to create an ongoing partnership with our customers.
entire storage retrieval system
To design, build, test and install a robust
system for handling, positioning and storing pallets of blank sheet
stock for a roll-forming process. The system included a way to
identify new pallets of blanks introduced via fork truck and track
them through the process by way of a bar code reader. The pallets are
placed in a storage rack and the system maintains pallet part number,
storage location and sheet quantity information. The system retrieves
pallets from the storage rack and positions them so that the
roll-former can remove one blank sheet at a time. The system retrieved
the pallets based on the blank part number and the number of blanks
required for each batch run. Empty pallets are sent to the unload
conveyor for fork truck removal. Partial pallets are returned to the
storage rack with updated part quantity information.
view of machine load station
The machine load station
assembly consists of a fabricated steel base frame containing two (2)
fabricated steel pop-up conveyors. The pop-up conveyors each
contain eight (8) electrically powered chain driven rollers and four
(4) pneumatic air bags with quick exhausts that control the raising
and lowering of the conveyors. A gravity roller is located at
the entry to the conveyors to assist the pallets as they transfer to
and from the stacker. The cross transfer reversing conveyor
contains chains that are powered by an electric variable frequency
drive and guided on rails.
view of storage rack
The storage rack consists of steel uprights and steel beams bolted
together to form the rack. Each rack bay contains a fabricated steel
fixture that the pallet rests on. A photo-eye reflector is mounted to
one leg of each steel fixture to ensure the stacker is in position to
allow the carriage to extend into the storage bay.
The stacker consists of a fabricated steel frame with a bolted
on fabricated steel carriage assembly. The stacker carriage
assembly contains a telescoping chain transfer device powered by an
electric brake motor. The chain transfer is mounted onto rails
and utilizes a pneumatic cylinder with flow controls to control
motion. The stacker motion and carriage motion is controlled by separate
electric servo motors with brakes. The stacker carriage utilizes a
ball screw assembly to move it up and down on steel rails. Urethane
bumpers are installed on the base frame of the stacker assembly to
protect the carriage in the event of an over-travel sensor failure. A
barcode scanner is mounted to the stacker carriage.
view of stacker rails
The stacker travels on steel rails bolted to steel track sections.
The track sections are bolted together to form one continuous track.
The track is anchored level to the floor in multiple places. The
stacker utilizes a pinion gear to guide it along the track. Rubber
bumpers are installed at the ends of the track to protect the stacker
carriage in the event of an over-travel sensor failure. A steel wire
way duct with steel cap sections is built into the center of the
track. The wire way houses all the power cables and pneumatic hoses
for the stacker device.
view of main control panel
The control logic and components for the Storage Retrieval System are
provided through the main control panel. The HMI operator interface
is mounted on the front of the Main Control Panel. A key switch is
located on the side of the panel. The key switch provides a system
override selection. The key switch can be placed in three (3)
separate positions; “Roll Mach”, “Both”, and “Pallet Conv”.