Intralogistics

Stacker cranes are a central component of an automatic storage and retrieval system (ASRS). These electrically operated, rail-mounted cranes move vertically and horizontally within the high-bay warehouse to store and retrieve goods. Depending on the system, the stacker cranes can be between six and eight metres high, while larger models can reach heights of up to 46 metres. With a speed of up to six metres per second, they enable fast and efficient warehousing, reduce space requirements and significantly increase productivity in warehouse operations.

Challenges:

• The assembly of stacker cranes is time-consuming and costly.
• The drag chain is often the weak point when it comes to maintenance.

LAPP solutions:

• Complete storage and retrieval machine connectivity package for easy installation.
• Reducing the number of suppliers and complexity for shorter assembly times.
• Highly reliable components to minimise downtime.

The carousel system is a subcategory of the ASRS and consists of containers that rotate on a predetermined rail – either horizontally or vertically. The system automatically rotates until the desired container is available at the right position for retrieval. This technology works at low to medium speeds and is particularly suitable for the space-saving storage of small parts. The high storage density makes optimal use of the available space.

Challenges:

• Series-produced machines sold worldwide, where a certain variability of sizes and configurations must be covered.
• Too many different suppliers and connecting components that cannot be sold globally.

LAPP Solutions:

• Optimised towing chain design, can be used worldwide.
• Various versions for different carousel systems.
• Reduction of suppliers and complexity for shorter assembly times.

A shuttle system in an automatic storage and retrieval system (ASRS) is a dynamic solution for storing and retrieving containers or pallets. The shuttles move autonomously within the racking structure and can either operate at a fixed level or switch between multiple levels using rails or lifts. These modular and scalable systems allow for a high degree of flexibility and can be expanded as needed. High throughput can be achieved by using multiple shuttles.

Challenges:

• High system complexity leads to high initial investment and maintenance costs.

LAPP Solutions:

• Cost reduction through the offer of prefabricated cable harnesses and modules.
• Reducing the number of suppliers and complexity for shorter assembly times.

An automated small parts storage system is an advanced storage system for the efficient storage and quick retrieval of large quantities of small parts. The fully automated and computer-controlled solution is often combined with ASRS systems, robotic grippers, shuttles and conveyor systems to achieve a particularly high storage density. The use of modern control software ensures fast and error-free picking.

Challenges:

• Not a series machine, high degree of modularity and customer-specific adaptation of the sensor/actuator cabling required.
• Focus on automation, usually little know-how on the connectivity side.
• Installation on site is time-consuming.
• Requires a high-quality and reliable cable system to minimise the risk of failure/maintenance.

LAPP Solutions:

• Design-In: Provision of expertise for the best choice of cabling.
• Standardisation of connection elements, suitable for every
• customer-specific requirement.
• Plug & play solution for quick assembly.

Conveyor systems enable the efficient transport, sorting and forwarding of goods within a warehouse or production facility. Motorised rollers or conveyor belts are used for this purpose. The systems can consist of individual modules or complex facilities. Thanks to their modular design, they can be flexibly adapted to modified transport routes, types of goods or throughput requirements.

Challenges:

• High modularisation for maximum flexibility or routing.
• High need for standardisation of components and interfaces to reduce complexity in all different modules.
• Installation on site is time consuming.

LAPP Solutions:

• Greatest depth of added value for each component: connectors, cables, assemblies from a single source.
• E2E connectivity to realise a modular design.
• Management of complex logistical requirements (e.g. just-in-time delivery for airport projects).

Autonomous mobile robots (AMR) and automated guided vehicles (AGV) are intelligent, self-driving vehicles that independently coordinate their routes and dynamically adapt to their environment. While AMRs calculate the optimal route to their destination completely autonomously, taking obstacles into account in real time, AGVs move along predefined routes. Both systems provide an efficient solution for the in-house transport of goods and significantly reduce the manual effort involved.

Challenges:

• Need for highly compact robot design.
• High iterations of robot generations with improved software, sensors and construction in general.

LAPP Solutions:

• Co-engineering and customised products to improve space, weight, EMC and routing.
• Design, prototyping and delivery of complete cable harnesses.

Sorter systems automatically identify, process and direct products to their designated storage or shipping areas. Sensors, cameras, barcode scanners or robots combined with data-driven software optimise the accuracy and speed of the processes. This technology reduces manual effort, minimises error rates and increases efficiency in logistics.

Challenges:

• Difficulty in finding sorting systems that can be easily reconfigured or scaled.
• Completely customised solution results in long lead time from purchase to delivery.

LAPP Solutions:

• Providing modular cabling systems that allow for easy reconfiguration and scalability without long downtime periods.
• Offering high-quality and durable cables that reduce the frequency of replacement and maintenance.

System installation and infrastructure encompasses the seamless networking of all relevant halls and facilities – from external building connections to complete integration within intralogistics. High-performance cables ensure a stable energy supply and enable the smooth operation of automated transport systems and highly complex storage solutions.

Challenges:

• Difficult installation of large cable dimensions without any flexibility.
• Difficult to purchase cables, cable lugs and crimping tools that are matched to each other.
• Difficult last-mile management for greenfield projects when the delivery address does not yet exist.

LAPP solutions:

• Support in converting to more installation-friendly cables or single-core variants.
• Complete system of products and tools for easy installation.
• Logistics service to coordinate last-mile management with GPS data.