Automation of a small parts conveyor system for connecting a shuttle warehouse
Initial situation
Our client is one of Europe’s leading suppliers of C-parts, specialising in fastening technology, connecting elements, custom and drawing-based parts, as well as production and maintenance articles. To meet growing efficiency and throughput demands, the warehouse processes needed to be automated.
Project scope
The objective was to implement a highly automated shuttle warehouse with 25,000 container storage locations, ensuring maximum space utilisation within the existing building. In addition, the warehouse had to be seamlessly integrated with automated guided vehicles (AGVs). The shuttle warehouse, installed by the general contractor, required high-performance small-parts conveyor technology to facilitate the transfer to the AGVs.
Our task was to network the shuttle warehouse and AGVs while ensuring the necessary data exchange between them. Both the handover and retrieval of goods by the AGVs are fully automated, ensuring high throughput capacity.
Our services
As part of the project, we were responsible for the electrical planning and implementation. The detailed electrical design – including the planning of control cabinets with all control components – formed the foundation for the precise and smooth operation of the entire system.
A key aspect of our work was clarifying interfaces with all parties involved. In certain areas, we developed custom interfaces to meet the project’s specific requirements. To reduce commissioning times and maximise software quality, we simulated the entire system in advance.
After the general contractor completed the mechanical installation, DriveCon took over the electrical installation. This included wiring and installing all electrical components on-site to ensure safe and stable operation.
Following the installation, we proceeded with commissioning, during which all components were tested, optimised and transferred into live operation. Comprehensive interface tests were conducted with all involved trades to ensure maximum throughput under all operating conditions.
Results and benefits
The automation of the shuttle warehouse resulted in a significant increase in throughput and a marked improvement in overall warehouse efficiency. Faster processes, reduced error rates and optimised workflows enable shorter delivery times, higher quality standards and increased customer satisfaction. At the same time, logistics flexibility has been significantly enhanced.
Our client benefits from greater adaptability in warehouse operations, as the system allows for rapid and precise responses to individual customer orders. End customers also gain advantages: thanks to transparent process control, they always know exactly when their orders will arrive, allowing them to plan their operations more efficiently.
With this solution, we have not only maximised efficiency but also sustainably strengthened the competitiveness of our client and its customers.
