Single-Row Multi-Tower Automated Storage System for Sheet Materials

Automation in sheet metal storage has historically been either too slow (vertical carousels with single access points) or too space-inefficient (automated guided vehicles running in wide aisles). The Herochu Single-Row Multi-Tower Automated Storage System for Sheet Materials breaks this deadlock by combining a linear single-row layout with multiple independent storage towers, each served by one fast, intelligent material cart. The result is a storage system that delivers sheet materials to production equipment with the speed of a conveyor and the density of a high-bay warehouse.

The mechanical architecture is straightforward yet powerful. The system consists of two to six (or more, custom) storage towers arranged in a single row. Each tower is a freestanding steel frame with multiple layers—typically 8 to 12 layers per tower, adjustable in 240 mm increments. A single gantry-style cart runs on ground-mounted rails along the entire length of the row. The cart carries a vertical lift stage and a telescopic fork that extends into the storage compartments. Unlike multi-row systems that require complex transfer cars to move between aisles, the Herochu single-row design keeps everything on one axis of horizontal travel. This simplicity translates directly into higher reliability and lower maintenance costs.

Speed is a defining metric for any automated storage system. Herochu has optimized the HC series for rapid material exchange. The transfer speed along the row ranges from 5 to 15 m/min, variable depending on load weight and operator preference. The vertical lift moves at a corresponding rate, synchronized to minimize total cycle time. When both axes move simultaneously (diagonal travel), the cart reaches the target layer in approximately 35% less time than sequential axis movements. For a typical retrieval from tower 1, layer 7 to tower 4, layer 3, the cart calculates the optimal path and executes retrieval within 60 seconds. The repeatability specification of ±1 mm ensures that the telescopic fork engages the sheet pallet exactly, without scraping or misalignment.

The automation extends beyond motion control. The Herochu system features a PLC-based touchscreen interface that consolidates all operation commands. One-touch delivery is the standard workflow: the operator selects a material ID or a tower/layer coordinate, presses “Retrieve,” and the cart fetches the sheet automatically. For factories with high material turnover, the system can be programmed to pre-stage a sequence of sheets. For example, a production manager can queue four different material types for the morning shift. The cart will retrieve each sheet in order and deposit them onto the unloading conveyor at programmed intervals. No human intervention is required between retrievals.

Precision picking is critical when dealing with metal sheets that may have sharp edges or delicate surface finishes. The Herochu telescopic fork is engineered with rubber-coated fingers or optional vacuum suction cups to prevent scratching. Load detection is redundant: the cart measures weight both before and after picking, confirming that the correct number of sheets was extracted. If the weight deviates by more than 2% from the expected value, the system pauses and alerts the operator via the touchscreen. This feature prevents mix-ups where two sheets stick together due to oil film or static.

The technical parameters of the Herochu Single-Row Multi-Tower Automated Storage System cover a wide range of sheet dimensions and capacities. The entry-level HC-S3015-2-63 supports sheets up to 3000×1500 mm, offers 3 storage towers (customizable to 2, 3, or more), and provides up to 6 layers per tower with a maximum per-level load of 3000 kg. The HC-S4015-3-85 increases sheet length to 4000 mm, uses 4 towers (customizable), and supports 8 layers at 5000 kg per level. For heavy industry, the HC-S6020-4-125 handles 6000×2000 mm sheets across 4 towers (customizable to 6 towers) with 12 layers per tower and the same 5000 kg per level capacity. All models share the same clear space (240 mm standard, adjustable), transfer speed range (5–15 m/min), and repeatability (±1 mm).

What makes this system truly automated rather than merely mechanized is its ability to handle exceptions. If a requested sheet is not in the expected tower location (perhaps due to a manual intervention that was not logged), the cart automatically performs a scan of all compartments in that tower to locate the sheet. If the sheet cannot be found, the system generates an inventory discrepancy report for investigation. Similarly, if the cart detects an obstacle in its path—a dropped tool, a pallet left on the rail—it stops, sounds an audible alert, and displays the exact location of the obstacle on the maintenance screen. The system then waits for clearance and resumes automatically, no reboot required.

Energy efficiency is another engineered advantage. The cart uses regenerative braking on both horizontal and vertical axes: when decelerating, the motors act as generators, feeding power back to the control cabinet. This reduces overall electricity consumption by approximately 18% compared to systems with dissipative braking resistors. Standby mode, activated after 10 minutes of inactivity, powers down all but the sensor monitoring circuits, consuming less than 50 watts. Given that a typical sheet metal storage system runs continuously during two shifts, these savings accumulate rapidly.

For plant engineers concerned about integration with existing material handling equipment, Herochu provides standardized interfaces. The unloading conveyor can be a roller conveyor, chain conveyor, or belt conveyor, positioned at the end of the single row or at an intermediate tower exit. The PLC communicates via Ethernet/IP, Profinet, or Modbus TCP, allowing the storage system to receive material requests directly from a laser cutter’s controller. When the cutter finishes a job, it sends a signal to the Herochu system to retrieve the next sheet—closing the loop between storage and production. This level of integration transforms the storage system from a standalone tool into a fully embedded component of the smart factory.