Automation of the central spare parts warehouse of Adolf Mohr Maschinenfabrik. One of the major highlights of this application is the innovative pick-by-light order picking station. A laser is used for optical signalling.

Tray storage systems

Baudock einer großen Werft (Quelle: Meyer Werft)
Baudock einer großen Werft (Quelle: Meyer Werft)

Beispielhaft für den Nutzen von Materialflusssystemen ist ein Großprojekt der Eckelmann AG für eine bekannte Werft: Das Leitsystem der Vorfertigung von Paneelen für den Schiffbau in Blockbauweise. Die Grenzen zwischen Materialfluss- und Produktionsleitsystem sind hier fließend.

Im Schiffbau ist eine Vielzahl unterschiedlichster Gewerke zu integrieren: Fräsen, Portalmaschinen zum Laser- und Plasmaschneiden, Schweißmaschinen, Robotik, Greifer, diverse Transportsysteme, Markierportale, Bildverarbeitungssysteme etc. Kurz: Eine so komplexe Fertigung wie im Schiffbau bedeutet Automatisierung in einem höchst heterogenen Anlagenumfeld – typisch für Materialfluss-Anwendungen in der industriellen Produktion. Dazu kommt die Lagerverwaltung, die optimal mit den Produktionsprozessen koordiniert werden muss.

Tray storage system
Tray storage system

Adolf Mohr Maschinenfabrik is a major manufacturer of high-speed cutters and high-quality cutting systems for the graphic arts industry. More than 125,000 of its machines have been installed to date. With a view to future requirements, a new service warehouse consisting of a tray storage system and a forklift-operated pallet warehouse was constructed at the company’s site in Hofheim.

In this, Eckelmann AG designed and implemented the automation of the entire warehouse management and order picking as well as the forklift guidance system. The core of the system is a convenient pick-by-light operator guidance at the order picking station of the tray storage system.

The automation solution for the tray storage system is based on Eckelmann’s  E•MAT modular software library for the standardisation of software solutions in logistics applications. The warehouse automation comprises the following sectors:

  • Connection to SAP via tRFC server. Standard and customer-specific IDOCs are used for communication.
  • Tray storage management for chaotic storage in ABC warehouse with additional height classification and route optimisation
  • Control of the picking stations for integrated order picking from heavy load carriers
  • Forklift guidance for the prompt supply and removal of goods to and from receiving areas and packing stations

Pick-by-light order picking station

Order picking station
Order picking station

Pick-by-light solutions are state of the art in one-man operated order picking shelves. Similar picking aids are rarely used for applications in service warehouses with “goods to man” transport of small-scale trays to a defined order picking station. Subsequent to the meticulous examination of available signal methods, Eckelmann AG decided on a highly flexible solution with software-controlled laser beam.

Optical signals are generated by a geometric figure. For this, a laser is used to draw a rectangle with its diagonals onto the targeted shelf.

This has the advantage that the tray geometry is freely configurable. All tray geometries and shelf divisions used are configured in E•MAT LV. A signal figure that is optimally adapted to the respective shelf is drawn for the current pick position.

Contact
Rudolf Schäfer
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