Advanced Automatic Plate Storage Warehouse Storage System – PLC-Integrated High-Density Sheet Metal Warehouse

The transition from ground piles to automated warehousing represents a quantum leap in sheet metal logistics. Herochu offers an Advanced Automatic Plate Storage Warehouse Storage System that functions as a complete, turnkey warehouse inside your existing building. Unlike simple storage towers, this system includes multiple inlet/outlet stations, automated cranes, conveyor interfaces, and full inventory management software. It is designed for manufacturers processing hundreds of different plate sizes, grades, and thicknesses daily.

Core Architecture of a Fully Automated Warehouse

Herochu’s advanced system uses a vertical rack structure with up to 13 floors, each capable of holding 3 or 5 metric tons. A high-speed extractor – often called a stacker crane – travels along linear guide rails to access any storage position. The extractor’s fork mechanism extends left and right to retrieve plates, then retracts and delivers them to the outlet conveyor. All movements are coordinated by a Siemens PLC with a 15-inch touch screen panel.

Automatic weight detection is integrated into every storage cycle. When a plate enters the system, load cells measure its exact weight. The PLC compares this value against preset limits. If within tolerance, the system logs the weight and selects an optimal location based on weight distribution rules – heavier plates go to lower floors to maintain structural stability. This automatic balancing extends rack life and ensures safe operation.

Seamless Integration with Production Lines

The advanced system is not a standalone island. Herochu builds communication bridges to laser cutters, shears, and punching machines. When a cutting machine finishes a nest and requires the next sheet, the warehouse system receives a call signal. It automatically retrieves the specified plate, transfers it to the outlet, and notifies the loader robot or operator. This closed-loop process reduces work-in-progress inventory and eliminates the need for intermediate storage tables.

For ERP connectivity, Herochu provides a standard API that exports transaction logs – time, plate ID, weight, location, and destination. Warehouse managers can run daily reports on material consumption and remaining stock. MES integration allows production schedulers to reserve specific plates for upcoming jobs, preventing conflicts.

Two Loading Modes with Enhanced Ergonomics

Like the single tower, the advanced warehouse supports forklift and overhead crane loading. However, the advanced system can incorporate multiple loading bays. For example, a large facility might designate one bay for incoming raw plates via forklift, another for returns of partial sheets via crane, and a third for direct feeding from a slitter line. The touch screen interface lets operators select which bay is active. Safety light curtains and interlocks prevent entry during automatic crane movement.

Performance Parameters That Drive Productivity

• Vertical lifting speed: 9 m/min (loaded), 12 m/min (unloaded)

• Horizontal travel speed: up to 30 m/min depending on rack length

• Inlet/outlet cycle time: typically 60–90 seconds per plate

• Positioning accuracy: ±2 mm

• Power supply: 380V/50Hz or customized

The chain drive transmission requires minimal maintenance – only quarterly lubrication of guide rails and annual chain tension check. Herochu includes a remote diagnostic modem as standard. Service engineers can log into the PLC to troubleshoot error codes, reducing downtime.

Case Example: Heavy Equipment Manufacturer

A construction equipment fabricator stored 2,000 tons of steel plates across 5,000 square meters of floor space. After installing a Herochu Advanced Automatic Plate Storage Warehouse Storage System with 12 floors and 5-ton per layer capacity, the storage footprint dropped to 400 square meters. Retrieval errors from misidentified plates fell to zero. The system now supplies two laser cutting lines and one plasma line simultaneously, with each line receiving plates within 90 seconds of request. Labor assigned to material handling decreased from four workers per shift to one.

Customization Options

Herochu designs every advanced warehouse from scratch. Plate dimensions can be any length from 3,000 mm to 6,500 mm and width from 1,500 mm to 2,500 mm. Floor count adapts to building height – typical installations use 8 to 13 floors, but 16-floor configurations exist for high-ceiling facilities. Load per layer options include 3T, 5T, or custom up to 8T with reinforced rack columns. Plate support selections range from fixed steel beams to adjustable cradles for curved or perforated sheets.

Long-Term Value

The Herochu Advanced Automatic Plate Storage Warehouse Storage System reduces floor space requirements by 70–80% compared to ground stacking. It improves inventory accuracy to 99.5% or higher. And it removes the safety hazard of unstable plate piles – a critical benefit for workshops with frequent seismic activity or heavy forklift traffic. For operations serious about Industry 4.0, this system provides the foundation for lights-out material handling. Request a feasibility study from Herochu to calculate exact ROI for your plate inventory profile.