Designing Automated Logistics Warehouse Stackable Bidirectional Infinite-Loop Modules
Abstract
:1. Introduction
2. Literature Review
3. Materials and Methods
3.1. Stackable Bidirectional Infinite-Loop Module Concept
3.2. Operation of Stackable Bidirectional Infinite-Loop Module
3.3. Pre-Transfer System
4. Experimental Design
4.1. Simulation
4.1.1. Current and Target Settings
- As-is fork liftGeneral logistics storage warehouse where logistics are transported using forklifts. There is a gap between the racks through which forklifts can travel;
- As-is stacker craneAutomated logistics warehouses use stacker cranes for logistics transportation. The racks were arranged so that the stacker cranes could travel through them;
- To-be stacker craneThe proposed automated logistics warehouse, in which logistics are transported to workers through a conveyer and stacker crane, eliminates the gap between the racks.
4.1.2. Experimental Design
- First experimentThe experiment was repeated 250 times, assuming that the number of logistics to be called was 100 PLT, and that one PLT was released in a first-in, first-out order;
- Subsequent experimentsThe experiment was conducted 250 times for 300, 600, 1000, and 1800 PLT logistics called. Logistics involve products that have a variety of small quantities and frequent outputs. The products to be called were tested such that they were released in order by random call or first-in, first-out.
4.2. Process Design and Implementation
5. Results
5.1. Experimental Results of Balanced Inventory Logistics
5.2. Experimental Results Using Virtual Bottleneck Phenomenon in Inventory Logistics
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Appendix A
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Rack Composition &Transfer Types * | Rack Columns | Rack Rows | Rack Tiers | Bay Width (m) | Bay Depth (m) | Bay Height (m) |
---|---|---|---|---|---|---|
As-is forklift | 20 | 30 | 3 | 50 | 1.1 | 7.5 |
As-is stacker crane | 6 | 30 | 10 | 50 | 1.1 | 21.75 |
To-be stacker crane | ||||||
Logistics specifications | Depth: 1.1 m, Width: 1.1 m, Height: 1~1.6 m | Logistics Call Quantity | Max 1800 PLT | |||
Number of logistics storage items | 1 | Rack Logistics Storage Method | Free Location |
Equipment | Horizontal Movement Speed | Vertical Movement Speed | ||||
---|---|---|---|---|---|---|
Min | Max | Avg | Min | Max | Avg | |
Stacker crane | 30 | 180 | 60 | 4 | 70 | 30 |
Conveyor (stack, transport) | 40 | 90 | 50 | - | - | - |
Lift (transport, module) | - | - | - | 6 | 60 | 45 |
Fork lift | 8 | 20 | 15 | 4 | 8 | 6 |
Inbound | Outbound | Ratio | |
---|---|---|---|
Distribution of logistics movement | 1800 PLT | 1800 PLT | 5:5 (equal) |
1080 PLT | 2520 PLT | 3:7 (inbound < outbound) | |
2520 PLT | 1080 PLT | 7:3 (inbound > outbound) | |
Total flow | Max 1800 PLT | Logistics call method | Random call based on first-in-first-out (FIFO) |
Picking ratio | 100% | In/outbound cycle | Single mode |
Command processing method | Single command |
Logistics Shipment Quantity (PLT) | Average Time (s) | Average Time (h) | |
---|---|---|---|
100 | As-is fork lift | 27,284.63 | 7.58 |
As-is stacker crane | 11,704.66 | 3.25 | |
To-be stacker crane | 7330.62 | 2.03 | |
300 | As-is fork lift | 82,156.09 | 22.82 |
As-is stacker crane | 35,029.83 | 9.73 | |
To-be stacker crane | 21,935.43 | 6.09 | |
600 | As-is fork lift | 164,489.20 | 45.69 |
As-is stacker crane | 69,972.45 | 19.43 | |
To-be stacker crane | 43,752.13 | 12.15 | |
1000 | As-is fork lift | 274,748.71 | 76.32 |
As-is stacker crane | 119,241.88 | 33.12 | |
To-be stacker crane | 73,041.91 | 20.28 | |
1800 | As-is fork lift | 494,373.59 | 137.32 |
As-is stacker crane | 214,393.35 | 59.55 | |
To-be stacker crane | 131,518.45 | 36.53 |
Logistics Shipment Quantity (PLT) | Average Time (h) | |||
---|---|---|---|---|
3:7 | 7:3 | 5:5 | ||
100 | As-is fork lift | 4.56 | 10.64 | 7.58 |
As-is stacker crane | 1.97 | 4.61 | 3.25 | |
To-be stacker crane | 1.21 | 2.84 | 2.03 | |
300 | As-is fork lift | 13.75 | 32.09 | 22.82 |
As-is stacker crane | 5.95 | 13.88 | 9.73 | |
To-be stacker crane | 3.63 | 8.49 | 6.09 | |
600 | As-is fork lift | 27.57 | 64.33 | 45.69 |
As-is stacker crane | 11.89 | 27.76 | 19.43 | |
To-be stacker crane | 7.29 | 17.02 | 12.15 | |
1000 | As-is fork lift | 45.79 | 106.84 | 76.32 |
As-is stacker crane | 19.87 | 46.37 | 33.12 | |
To-be stacker crane | 12.17 | 28.40 | 20.28 | |
1800 | As-is fork lift | 82.39 | 192.25 | 137.32 |
As-is stacker crane | 35.73 | 83.37 | 59.55 | |
To-be stacker crane | 21.91 | 51.14 | 36.53 |
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Min, K.; Lim, D. Designing Automated Logistics Warehouse Stackable Bidirectional Infinite-Loop Modules. Appl. Sci. 2023, 13, 12472. https://doi.org/10.3390/app132212472
Min K, Lim D. Designing Automated Logistics Warehouse Stackable Bidirectional Infinite-Loop Modules. Applied Sciences. 2023; 13(22):12472. https://doi.org/10.3390/app132212472
Chicago/Turabian StyleMin, Kyoungsoon, and Daeeun Lim. 2023. "Designing Automated Logistics Warehouse Stackable Bidirectional Infinite-Loop Modules" Applied Sciences 13, no. 22: 12472. https://doi.org/10.3390/app132212472
APA StyleMin, K., & Lim, D. (2023). Designing Automated Logistics Warehouse Stackable Bidirectional Infinite-Loop Modules. Applied Sciences, 13(22), 12472. https://doi.org/10.3390/app132212472