duosys1Government regulation and increasing long-term energy costs demand that companies in the intralogistics sector now develop highly efficient facilities. Significant improvements can be made in such areas as control systems, weight optimization of equipment and scalability. Here DAIFUKU Europe Limited offers real solutions.

Every lift in operation today functions on the same basic principle: Counterbalance weights provide the lift with high energy efficiency. So it is all the more surprising that counterweights are not being used in every case where loads are being lifted and lowered. Many of the automated storage and retrieval (AS/RS) systems on the market today are still not using this technology. One of the few exceptions to this is DAIUKU: For many years now the Japanese world market leader in materials handling solutions has been equipping its products with counterweights and thus reducing consumption of electricity.

This type of design engineering is a small part of the “Basic Environmental Policy” with which DAIFUKU established as early as 1999 the responsible use of resources as a specific company goal.

gubesch034As the intralogistics specialists of the day, this move put them about ten years ahead of their time. Concern for energy usage is only just now catching on more widely in this sector. Developments in this area are currently getting an additional boost from political resolutions and decisions. The EU’s energy policy action plan requires a reduction in CO2 emissions by 30 percent by the year 2020 – in relation to 1990 levels. As a critical measure for the implementation of this goal, the increase in energy efficiency was set at 20 percent.

Assessment is difficult

These EU guidelines were specified in Directive 2005/32/EG, also known as Eco-design or the EUP directive, by the European Parliament and the European Council of July 6, 2005. The directive deals mainly with the environmentally compatible design of energy-operated products and was adopted into national law in Germany on March 7, 2008 under the awkward name of the “law for energy-operated products”. The law’s first real success was a commercial ban on light bulbs. However, assessing energy efficiency in the area of materials handling equipment and systems is more difficult than in the area of lighting. “The preliminary requirements still must be met in order to make objective comparisons in this area”, says Werner Gubesch, Manager of Engineering at DAIFUKU Europe in Mönchengladbach.
This will not happen quickly – the individual solutions in this area are too far-reaching and extensive.

Reduced weights

1_daifuku-sorting-transfer-vehicleRegardless of this fact, manufacturers are already detecting an increase in the demand for energy-efficient materials handling solutions. Gubesch is convinced that this trend will continue in coming years. This is due “partly to increased energy costs and partly to political influences”. “Even today, performance criteria such as throughput and dynamics are no longer deciding factors for investments”, observes his colleague Thomas Balluff, Director of Factory Automation & Distribution Automation (FA & DA) at DAIFUKU Europe Ltd. He also notes: “Within the scope of invitations to tender, systems energy consumption is becoming more important.” Energy consumption depends greatly on the weight of the objects that must be moved. Because of this, DAIFUKU has in recent years drastically reduced the dead weight of their AS/RS machines. This allowed them to minimise the driving power and thus the energy consumption of their motors, but with equal or greater dynamic values. One example is their H-class Pallet storage and retrieval system, which is manufactured up to a height of 40 metres and whose weight has been reduced by 25 percent. This was accomplished mainly by completely redesigning the mast. This solution consists of a combination of lattice mast material and profiled steel tubing. These construction measures are complemented with sophisticated control concepts such as the counteracting of mast vibrations during acceleration and deceleration.

Retrofitting and upgrades are possible at any time

In regard to compact and lightweight construction, the new generation of highly dynamic machines used for automated small parts storage are also setting the standard for DUOSYS applications with an equipment weight of less than 350 kilograms. The most impressive aspect of this system is its dual cycle rating of 1,100 cycles per hour. Another significant advantage of the DUOSYS concept is the scalability of the system.  Initially only one AS/RS device per aisle can be operated. Later, when the anticipated projected growth rates have been attained, aisles may be upgraded with additional machines. This flexibility also allows for further upgrades after the initial upgrade. This makes it possible to automatically reduce or even shut down the dynamics of one or both machines used for automated small parts storage on a particular aisle. The machines can be switched on again automatically at any time if necessary. Materials handling expert Gubesch is convinced that “this scalability of logistical systems and facilities will increase in significance”.

warehouse-and-storage-retrieval-machine-300dpiSystems of this type allow companies to adapt gradually to anticipated changing performance requirements. It is no longer necessary to equip a new logistics facility with excess capacity in anticipation of its future growth. As a result the investment can be distributed over a longer period and also energy efficiency can be improved. This increase in energy efficiency is accompanied by the gradual growth of the facility itself, which is always of the optimal size.

Electricity instead of heat

DAIFUKU customers have known about the advantages of scalable systems for a long time. A proven example of this is the so called sorting transfer vehicle – STV for short – used in the supply zone, or “pre-zone”, of high bay warehouses. The so-called “STV loops” have established themselves there as an alternative to conventional conveyer lines. In comparison to static systems with permanently installed and constantly operating conveyer components, the highly dynamic shuttle vehicles used by STV loops allow for significantly more flexible and efficient system use. Any future performance requirements specified for the facility may be integrated into the concept even in the planning stages of these STV pre zones. This means that achieving increased performance by adding additional vehicles later is much easier and more affordable than it is with conventional conveyer technology. Energy recovery offers yet another potential area where costs may be reduced. For several years DAIFUKU has been manufacturing AS/RS devices with drive systems capable of converting kinetic energy generated by braking operations into electricity and storing it. “In the meantime, this technology has advanced and matured” emphasizes Thomas Balluff, adding: “Negative circuit feedbacks which are outside the allowable limits of the EMC norms will be completely out of the question.” The technology is well worth it: Depending on weight and dynamics, energy recovery units can achieve cost reductions of between 10 and 25 percent. Energy expert Gubesch also sees savings potential in the demand managementl of materials handling solutions: “It must be possible to adjust the systems quickly. High dynamics are required during peak periods and minimum dynamics during normal operations.” DUOSYS offers an impressive example in this area as well. The modern control system of the light-weight units allow them to selectively reduce or increase the machine’s dynamics. The drive assembly’s power consumption is significantly optimised by the use of performance-related set-point inputs. The result of this and other measures is a power consumption of approximately 30 kVA per module. Bear in mind that this value applies to a single DUOSYS module which consists of four mini load machines for automated small parts storage split over two levels. This is about 30 percent lower than with conventional automated mini load systems. For “retrofitting” of existing facilities, modern control systems are one of the most important components for achieving greater energy efficiency. The intelligent software that is used by Daifuku can be upgraded easily and simply by module. The modernisation business offers major opportunities for operating companies, equipment manufacturers and the environment.

daifuku-logo-mh-and-beyond-300dpiDAIFUKU Europe Limited

Thomas Balluff

Telephone: 02161-49695-0

Email: info@DAIFUKU.de

www.DAIFUKUeurope.com

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