The list of IFOY nominees: Cube-shaped robotic storage systems are experiencing a boom. e.scala is a highly standardized goods-to-person system that uses a robot to replace all the classic components of an automated warehouse and can be installed in just three months.
The e.scala is a robot-based storage and order picking system in which the robot moves in three dimensions within a storage cube and easily reaches any point in a warehouse or production area via a rail system. A patented ramp system allows the robots to move from one storage level to another and overcome height differences outside the storage cube. Its high degree of flexibility allows virtually any customer requirement to be met using standard modules.
During the IFOY test days in Dortmund, the ramp assembly was lifted into the test hall as a single unit. The only moving part is the rail-mounted shuttle, which stow – for simplicity's sake – calls a "robot." Otherwise, the customer receives complete redundancy. e.scala's strength lies in its relatively straightforward entry into automation.
One of its unique features is that the entire system consists of only 15 different parts. However, the test camp only showcased the "exciting" warehouse pre-zone with three lines for accessing the warehouse's four levels. The system's functionality is reflected in its product name: the "e" stands for escalator, and the term "scala" is meant to demonstrate its scalability. The entire installation operates without a vertical lift, meaning no elevator is required: access to the individual aisles is via inclined ramps, which significantly reduces the potential for errors. The section where the robot can change direction is called the "Connector," allowing it to transport goods into or out of the warehouse and, with or without cargo, to change levels.
Photo: IFOY / Schütze
In principle, as the auditors in the IFOY audit also noted, the system resembles a parking garage, although the actual order processing system is usually located outside the warehouse. The manufacturer also places great emphasis on the system's redundancy: according to the manufacturer, the only thing that could break down is the robot. However, this would not block the entire system.
The transport robot has eight wheels: four for travel in the X direction, and the other four move the robot in the Y direction after the wheel change. Essentially, the entire setup requires power only twice: once for the charging station where the individual robots can recharge their power packs – with a charging time of eight seconds, they can travel for about twelve minutes – and once for the Wi-Fi communication between the robots and the warehouse management system. This also means that no cables are installed in the entire receiving area.
The individual modules of the e.scala system measure 5.0 meters x 2.5 meters and are scalable. The system can easily handle a total height of 24 meters. When the robot travels over the integrated passive RFID tags in the respective track section, the Stow Traffic Control (STC) system is notified.
Because the system is highly standardized, even small-scale requirements starting at 500 automated storage locations can be easily met. Since the system's 15 basic components and the robot can be delivered directly from stock, a complete system can be planned and implemented in a very short time. Even in the event of a robot failure, system availability is exceptionally high, as access to every storage location is guaranteed at all times via multiple access points.
Because low initial investments and easy scalability are of great importance for the automation of smaller systems, e.scala seems ideally suited for SMEs that do not want to go all in with their investment in automated intralogistics.
The actual IFOY award winners will remain a secret until the very end. The IFOY gala and awards ceremony will take place on June 30th at BMW Welt in Munich.
