Per System Block:
A stacker crane operates in the central aisle between 2 rack rows.
Section 4 Bucket Automated Storage & Retrieval System (Bucket AS/RS) Installation Area & Capacity Calculation
Basic Structure of Bucket AS/RS and Container Totes (Buckets)
A Bucket AS/RS (Mini-Load Tote AS/RS) is a high-density, multi-tier storage system utilizing specialized container totes (buckets).
- Basic Configuration: Each system block consists of 2 rack rows with a stacker crane operating along the central aisle to perform storage and retrieval.
- Cantilever Rack Structure:
- Container totes (buckets) span across extending arms (cantilevers) attached to rack upright posts.
- The crane's extractor mechanism extends sliding plates beneath tote bottoms to lift and retrieve containers.
- Container Standardization Limits: Stores standardized, rigid container totes (buckets) exclusively. Non-standard dimensions or structurally weak cardboard boxes cannot be stored directly.
Operations and Picking Workflows
Inbound and outbound conveyors are positioned at the front of Bucket AS/RS racking blocks to execute the following workflows:
- Retrieval Methods: Supports full-container retrieval or piece picking where workers retrieve specific item quantities directly from totes.
- Piece Picking Workflow: Workers pick required item quantities from retrieved container totes (buckets), after which the container with remaining stock is automatically returned to storage slots.
- Workplace Ergonomics: Requires adequate material handling aisles and conveyor staging floor space to enable efficient worker movements.
Engineering Dimensions and Setback Clearances
Modifying Tera Settings parameters automatically updates automated Bucket AS/RS calculations matching revised engineering parameters.
Dimension Calculation Example
Standard calculation parameters for Size-51 tote containers (550 mm width) are as follows:
| Parameter Item | Sample Dimension Settings |
|---|---|
| Total Rack Block Width | 1,910 mm (555 mm rack depth × 2 rows ＋ 800 mm crane aisle width) |
| Building Wall Clearance | 200 mm (Setback margin between building walls and rack structures) |
| Inter-Block Clearance | 150 mm (Gap between adjacent parallel crane blocks) |
Rack Structural Components
Rack structures are divided into functional structural tiers—including "Bottom Tier", "Top Tier", "Braced Structural Tier", and "Standard Tier"—all incorporated into floor area calculations.
Calculation Interface
Racks Employ a Cantilever Support Format
Extended plates (cantilevers) project from rack upright posts, supporting container totes (buckets) resting across them.
A sliding plate from the traveling crane's extractor mechanism enters beneath the tote, lifting the bottom to pull the container onto the crane carriage.
Requires rigid container totes (buckets) of exact specification dimensions; containers of differing dimensions cannot be stored. Even if dimensions match, non-rigid containers like standard cardboard boxes cannot be stored directly.
Inbound/outbound conveyors sit at the front of rack blocks where operators execute receiving and dispatch tasks. Material handling aisles are also required.
Supports full-tote dispatch and piece picking.
In piece picking, operators pick items from retrieved container totes (buckets) and automatically re-store the container.
Rack Structural Classifications:
Divided into Bottom Tier, Top Tier, Braced Tier, and Standard Tier.
Modifying Tera Settings parameters dynamically updates automated area calculations.
Rack Block Width:
For Size-51 containers (550 mm width):
555 mm rack depth * 2 rows + 800 mm crane aisle = 1,910 mm width.
Building wall clearance = 200 mm.
Inter-block clearance between 2 crane blocks = 150 mm.