Careers
3D Automated Pallet Shuttle
High-density pallet storage system employing autonomous, multi-directional shuttle cars to maximise warehouse capacity, productivity and flexibility.
The product
The ultimate automation solution for maximising high-density storage, productivity and flexibility in an automated storage and retrieval system (AS/RS) for pallets
The 3D Automated Pallet Shuttle is a high-density storage solution featuring an innovative multi-directional electric shuttle. This autonomous shuttle car stores and retrieves pallets from racking with unparalleled efficiency and precision. Notably, these shuttles navigate the aisles and channels within the racking structure independently, eliminating the need for additional material handling vehicles (e.g., stacker cranes or transfer cars). To move between storage levels, the shuttles employ a series of lifts.
Mecalux’s 3D Automated Pallet Shuttle is a cutting-edge AS/RS at the forefront of warehouse automation. In addition to increasing warehouse productivity and optimising space utilisation to boost storage capacity, it provides extraordinary versatility. This flexibility allows businesses to meet the requirements of dynamic scenarios, such as demand peaks and high-priority tasks. Moreover, its completely modular design enables rapid scalability to tailor the AS/RS’s capacity and throughput to business growth.
Advantages of the 3D Automated Pallet Shuttle
- High productivity: the rapid navigation speed and operational versatility of the multi-directional 3D shuttles significantly enhance warehouse performance.
- Maximum flexibility: the shuttle cars move between levels and aisles. Additionally, several shuttles can operate in a single aisle simultaneously. This allows managers to adjust the system’s throughput to changing scenarios, including the execution of priority tasks and the occurrence of demand peaks.
- Greater capacity and diversification: compact storage optimises the use of space to increase warehouse capacity. Moreover, each channel can house more than one SKU and pallet size.
- Autonomous, smart operation: the shuttles move through the aisles and channels without assistance from other material handling vehicles. Mecalux’s fleet management software controls shuttle traffic in the racking structure. This ensures continuous and fluid vehicle circulation, prevents jams and avoids collisions between shuttle cars.
- Operational efficiency and agility: a series of sensors ensure safety and effectiveness in detecting, handling and positioning pallets. Moreover, the design of the wheels and rails enables the shuttle vehicles to run smoothly and change direction with ease and stability.
- Scalability: the AS/RS’s modular design facilitates future expansion tailored to business growth. To increase productivity, new shuttles can be added. Likewise, new aisles and levels can be created to expand capacity.
- Wide temperature range: the shuttles’ ability to operate at low temperatures makes them suitable for cold-storage and freezer warehouses. The implementation of high-density solutions in such facilities provides considerable savings in energy costs.
- Comprehensive solution: Mecalux designs, manufactures, installs and commissions all AS/RS components. These include the shuttles, lifts, racking, conveyors, fleet management software and warehouse management system (WMS).
Applications of the 3D Automated Pallet Shuttle
High-density automated storage and maximum productivity
The 3D Automated Pallet Shuttle is the AS/RS solution best suited to scenarios with intensive loading and unloading cycles or high variability in demand. Its compact design leverages available space, while its versatility makes it adaptable to the requirements of companies in multiple sectors.
Warehouses with high product turnover
This AS/RS is perfect for considerably streamlining the management of facilities with large daily volumes of incoming and outgoing palletised loads.
Facilities with large-scale storage
It is the ideal solution for companies with large quantities of pallets per SKU. Its high-density storage expands warehouse capacity, while the operational speed of the shuttle ensures maximum performance.
Cold-storage and freezer warehouses
The 3D shuttle’s wide range of thermal resistance allows for its implementation in cold stores. In these spaces, high-density storage reduces the space to be cooled, lowering costs and freeing operators from working in low temperatures.
How does the 3D Automated Pallet Shuttle work?
The multi-directional movement of the 3D shuttle cars through the racking block greatly enhances the system’s flexibility. This streamlined operation significantly facilitates pallet loading and unloading, making this AS/RS adaptable to various demands.
A pallet arrives at the racking block
The conveyor, located at the entrance to the AS/RS, moves the pallet to be stored to the racking entry point. Along its path, the pallet passes through a checkpoint to inspect its dimensions (for clearance) and deckboards.
A 3D shuttle picks up the pallet for putaway
The WMS software assigns the pallet the optimal position. Meanwhile, the fleet management software determines the most appropriate route to reach this location. It sends the information via a Wi-Fi signal to one of the shuttles, which picks up the pallet and begins its journey through the racking.
The shuttle transports the pallet to an upper level
If the assigned location is on a higher level, the shuttle uses an entry lift to move to that height. Access to the upper levels can vary depending on the configuration chosen: for example, the shuttle can also deposit the pallet on a lift for another shuttle to collect it at the destination level.
The shuttle moves within the racking
Once at the assigned level, the shuttle car navigates the aisles until it arrives at the entrance to the indicated channel. The fleet management software coordinates shuttle traffic, while sensors regulate the speed of shuttles approaching each other. Thus, shuttle vehicles moving simultaneously in the same aisle do so smoothly and safely. Shuttles can change aisles by means of transit channels (if loaded) or storage channels (if unloaded).
The shuttle places the pallet in the assigned location
When the 3D shuttle reaches the storage channel, it raises the pallet slightly and enters the channel, depositing the load in the deepest available location. The shuttle car stores the goods as compactly as possible, irrespective of the size of the pallets in the channel. When using the LIFO (last in, first out) method, the software can establish an internal division within the channel to house different SKUs on either side (when both ends face an aisle).
The shuttle exits the channel and reintegrates into circulation
After depositing the pallet, the shuttle car can leave the channel from the side it entered. Alternatively, it can pass underneath the stored pallets and exit at the opposite end (if the channel opens into another aisle). The software will indicate the precise moment for the shuttle to rejoin circulation and complete its next task.
Shuttle battery recharging process
The shuttles continuously report the status of their batteries. When a shuttle’s charge is detected to be below a certain level, the fleet management software directs it to one of the charging stations strategically located within the racking block. Once recharged, the shuttle automatically returns to work, without the need for human intervention in the process.
3D Automated Pallet Shuttle components
In the 3D Automated Pallet Shuttle system, the shuttles and lifts control all pallet movements within the racking structure. This significantly simplifies its design and implementation compared to other high-density AS/RS solutions, as there is no need for additional handling equipment such as stacker cranes or transfer cars.
With its compact design, ample autonomy and high load capacity, the 3D shuttle is the system’s operational powerhouse. Its 12 translation wheels enable its multi-directional navigation as well as agile, stable movements.
The 3D system’s racking consists of compact and robust high-density structures. They stand out for their extensive rail circuit designed to facilitate the multi-directional movement of the shuttles.
Lifting platform
Located on the top of the shuttle, it slightly raises the pallet, enabling it to move through the channels. There are two configurations. The first is compatible with pallets measuring 800 x 1200 mm and 1000 x 1200 mm. The second accommodates pallets with dimensions of 1200 x 1200 mm in addition to the aforementioned sizes.
Sensors
The shuttle car incorporates several sensors to enhance its operational effectiveness. They fulfil different functions, such as verifying the correct positioning of the pallet on the shuttle, detecting the last pallet deposited in the channel and calculating the distance to another shuttle in front of it.
Channel running wheels
Set of 8 translation wheels (4 driving and 4 non-driving) that sit on the base of the storage channel rails to enable the shuttle to move inside it.
Channel guide wheels
Group of 6 wheels that reinforce the longitudinal guidance of the shuttle as it moves within the channels.
Aisle running wheels
Set of 4 translation wheels (2 driving and 2 non-driving) that rest on the aisle rails, allowing the shuttle to move along the aisle.
Aisle guide wheels
Group of 4 wheels that guide the shuttle as it navigates the aisles, ensuring stable movement.
Battery
Shuttle cars use batteries with very fast charging cycles, making these vehicles highly autonomous. Battery charge levels are constantly monitored; thus, shuttles are automatically moved to a charging station when necessary.
Antenna
Device through which the shuttle car receives instructions (via Wi-Fi) from the WMS and fleet management software.
Frames and beams
Vertical and horizontal profiles. Together with the rails, they form the racking framework where 3D shuttles navigate through aisles and storage channels to store and retrieve pallets.
Rails
Horizontal profiles along which the 3D shuttle vehicles travel. Rails are located on the different levels of the main aisle and inside each storage channel. The channel rails also serve as the support surface on which the pallets are deposited.
Lifts
High-performance load-raising devices used to connect the different levels. A minimum of two lifts are installed (one inbound and one outbound). However, the number can be extended to increase the operational capacity of the AS/RS.
Safety mesh
Safety element consisting of metal mesh that prevents loads from falling. It is fitted along the full height of racking blocks adjacent to passageways.
Safety partitioning
Perimeter metal fencing that delineates the block of racking, the operating area of the 3D shuttles and lifts, and the conveyor located at the front of the AS/RS.
Catalogues
3D Automated Pallet Shuttle
Maximum high-density pallet storage and operational productivity
Download
Ask an expert