Overview of Automated Storage and Retrieval Systems
Automated Storage and Retrieval Systems (ASRS or AS/RS) are computer and robot-aided systems that can retrieve or store items in specific locations. ASRS may consist of aisles with shuttles, crane, carousels, vertical lifts, etc., and are widely used in manufacturing, distribution facilities, and other settings.
ASRS offer high-density storage (providing considerable space savings), contribute to optimising operations, and help reduce the costs of manual labour. However, they are vulnerable to power outages, subject to breakdowns, and require regular maintenance.
There may be situations where personnel need to access the aisles (e.g., to perform maintenance tasks). Since ASRS involve moving parts, conveyors, and possibly robotic arms, operators can be exposed to hazards, getting caught in moving machinery with the risk of body parts being trapped or crushed.
The Challenge
Fortress Safety worked with a global technology leader in high-speed automation and material handling, to design and provide safety solutions for an innovative ASRS in New Jersey, USA. The system consists of multiple aisles, with guards at each end to allow access, as well as side access guards.
The customer identified the need for safety solutions in the form of interlocks to address situations where there is whole body access and protect their personnel when access to the aisles is required. They were also looking for a solution that could be easily scalable to adapt to changing business needs and growth (i.e., to accommodate future expansion or shifts in operational strategy). Moreover, since other devices on site communicate over EtherCAT, the customer required a solution that could be easily integrated into their existing network.
Overview of solutions for high-speed automation and material handling system
Our Safety Solutions with EtherCAT
Fortress offered devices for aisle access and remote safety I/O capability through devices able to communicate over EtherCAT. Three types of units from the amGardpro range were provided, allowing for aisle access, side access, and remote I/O respectively.
At the access points, two interlock configurations were used. In particular, the amGardpro interlocks had the following features:
✅ Single action escape release handle
✅ Guard locking (power to unlock)
✅ Auxiliary release (for the end of row access units) or emergency release (for the side access units)
✅ Illuminated emergency stop and pushbuttons
The configuration for side access was used in four locations, while the one for end of row access was used in ten locations. The remote I/O units to allow the connection of E-stops or other ancillary safety devices onto the EtherCAT network were installed at eight different locations inside the safeguarded space.
Interlocks with emergency release for side access
Interlocks with auxiliary release for end of row access
Remote safety I/O units
The Key to Success
We were able to provide a solution tailored to the customer’s needs, addressing the requirements of their specific application. For this partnership we also developed a connector base that utilises L-coded M12 connectors instead of the larger 7/8” variants. This will be used for amGardpro solutions that will be installed at other locations.
This project was made possible thanks to the cooperation of the various parties involved. Throughout the whole process, experts from Fortress Safety worked closely with the customer, offering advice, and ensuring optimal operation, together with Shingle & Gibb Automation (our channel partner), and East Coast Automation (our manufacturing rep).
Shingle & Gibb Automation provide products for industrial automation and networking, motion control, machine safety and power transmission. East Coast Automation is a manufacturers rep firm servicing the mid-Atlantic market.
Fortress Safety and Warehouse Automation
The products described in this case study were selected based on the requirements for a specific customer. Fortress offers a variety of safety solutions suitable for the warehouse automation industry, encompassing multiple applications and machines.
Fortress devices may also be used as part of a wider system to meet the requirements of EN 528:2021+A1:2022 – Rail dependent storage and retrieval equipment – Safety requirements for S/R machines. This is a European standard that includes a range of requirements for ASRS, including key dependency and mode selection.
Contact our team to find out about how our products can meet your specific application requirements.
Alternative solutions
This solution successfully resolved a challenge for a specific customer. Fortress can accommodate alternative setups and/or multi-range options. Share your application details with us so we can design a bespoke solution to meet your needs.
