Customizable Automatic Plate Storage Warehouse Solution

No two metal fabrication shops are identical. Plate sizes vary from small blanks to 6-meter-long ship plates. Weights range from thin aluminum sheets under 100 kg to armor-grade steel plates exceeding 5 tons. Ceiling heights differ, existing material handling equipment differs, and production line layouts differ. Herochu’s Customizable Automatic Plate Storage Warehouse Solution addresses this diversity through modular design. Every parameter – number of floors, load per layer, plate dimensions, movement speeds, and control logic – can be tailored to the customer’s exact specifications.

Modular Architecture for Unlimited Configurations

Herochu starts with a standard building block: a vertical rack column with linear guide rails and chain drive. Each column supports one storage tower. Multiple towers can be placed side by side and served by a single extractor on a common horizontal rail. Alternatively, each tower can have its own dedicated extractor for higher throughput.

The customization parameters include:

• Plate dimensions: Standard widths from 1,500 mm to 2,500 mm; lengths from 3,000 mm to 6,500 mm. Custom sizes up to 8,000 mm x 3,000 mm available on request.

• Number of floors: 8 to 13 as standard; 4 to 16 as custom. The exact count depends on building clear height and plate thickness profile.

• Load per layer: 3T or 5T standard. For heavy plate applications, Herochu offers reinforced racks rated for 8T, 10T, or 12T per layer.

• Plate support options: Fixed crossbeams, roller beds for easy sliding, V-shaped cradles for round or curved materials, or magnetic chucks for ferrous sheets.

• Movement speeds: Standard vertical lift is 9 m/min. Optionally upgrade to 15 m/min or 20 m/min for faster cycle times. Horizontal speeds can reach 40 m/min with servo motor upgrade.

Control System Customization

Herochu’s PLC base is Siemens S7-1200 or S7-1500, but customers can specify Allen‑Bradley, Mitsubishi, or Omron for plant standardization. The touch screen interface can be customized with the customer’s logo, preferred color scheme, and local language. For advanced users, Herochu can supply a PC-based control system with SQL database integration.

Connectivity options include:

• Ethernet/IP, Profinet, or Modbus TCP for ERP/MES

• OPC UA server for IIoT data collection

• Barcode or RFID reader integration at inlet/outlet

• Remote monitoring dashboard via web browser

Real-World Custom Examples

Example A – Automotive Tier 1 Supplier
Requirement: Store 4,000 mm x 2,000 mm blanks, 2T each, 40 different material grades. Ceiling height only 6 meters.
Herochu solution: 8-floor tower with 3T per layer, roller bed supports for easy blank transfer to destacker. Added RFID tags on each blank for grade tracking. Cycle time: 55 seconds per blank.

Example B – Heavy Plate Fabricator
Requirement: Store 6,000 mm x 2,500 mm plates up to 8T each. Limited floor space. Overhead crane only for loading.
Herochu solution: Single tower with 6 floors, reinforced columns, 10T per layer rating. V-shaped supports to prevent plate warpage. Crane loading mode with laser positioning assist. Vertical lift speed reduced to 6 m/min for safety with heavy loads.

Example C – High-Mix Low-Volume Job Shop
Requirement: Store 300 different plate sizes from 500 mm x 500 mm up to 3,000 mm x 1,500 mm. Need random access.
Herochu solution: Two towers side by side with shared extractor. 12 floors in each tower. Adjustable plate supports that accommodate variable lengths. Touch screen includes photo search – operator selects a thumbnail image of the plate to retrieve.

Engineering and Installation Process

Herochu follows a five-step customization process:

1. Site audit: Measure building dimensions, ceiling height, existing equipment, and power supply.

2. Plate portfolio analysis: Customer provides list of all plate sizes, weights, and monthly throughput volumes.

3. Design proposal: Herochu delivers 3D CAD drawings showing rack layout, extractor travel paths, and safety zones.

4. Factory acceptance test: Custom system is assembled at Herochu’s facility and run with dummy plates matching customer’s weight and size profile.

5. On-site installation and commissioning: Typical timeline is 10–15 working days for a single tower, 20–25 days for multi-tower systems.

Safety and Reliability in Custom Designs

Every customizable solution includes standard safety features: overload protection, limit switches, emergency stops, and light curtains. For custom high-load applications (above 5T per layer), Herochu adds structural finite element analysis reports, seismic bracing, and redundant chain drives. The chain drive transmission is derated to 60% of its maximum capacity to ensure long life under custom heavy loads.

Investment and ROI Considerations

A customized Herochu automatic plate storage warehouse typically costs 20–30% more than a standard tower, but the productivity gains are proportionally higher. Customers report:

• 60–80% floor space reduction

• 70–90% retrieval time reduction

• Zero plate damage from stacking

• Inventory accuracy above 99%

Payback periods range from 12 to 30 months depending on labor costs and material value. Herochu provides a detailed ROI calculator as part of the design proposal, factoring in local labor rates, floor space rental or depreciation, and scrap reduction.

Why Choose Herochu for Customization

Herochu maintains an in-house engineering team dedicated to custom projects. Unlike competitors who force customers into rigid product families, Herochu designs each system from the ground up. The company holds ISO 9001 certification and uses only certified steel from mills with material traceability. Every weld on a custom rack is inspected by magnetic particle or dye penetrant testing. For global customers, Herochu ships knockdown kits for local assembly or provides full installation crews. The customizable automatic plate storage warehouse solution is the answer when standard products fall short. Send Herochu your plate storage challenge – no matter how unusual – and receive a design within two weeks.