Gantry-Based Long Goods ASRS | Herochu Automated Storage & Retrieval

Long goods—defined as materials whose length exceeds three times their width—include pipes, tubes, bars, rods, rails, and structural sections. Their storage has traditionally required large floor areas, low-density racks, and significant manual labor. The Herochu Gantry-Based Long Goods ASRS (Automated Storage and Retrieval System) brings the principles of high-density automated warehousing to the long goods category. By combining a fast-traveling gantry crane with mobile shelf towers, precision sensors, and advanced warehouse control software, this ASRS achieves storage densities comparable to vertical lift modules (VLMs) but for materials up to 8,000 mm in length. This article explains the technology, benefits, and technical specifications of the Herochu solution.

ASRS Fundamentals Applied to Long Goods

Conventional automated storage and retrieval systems are designed for unit loads on pallets, typically with dimensions not exceeding 1,200 mm x 1,000 mm. Scaling such systems to 8-meter-long materials would require prohibitively large aisle widths and crane spans. The Herochu gantry-based approach uses a different paradigm: the storage shelves are arranged in rows parallel to the gantry’s travel direction. Each row consists of multiple independent tower racks that move on floor-mounted rails. When the gantry needs to access a specific shelf, the two adjacent towers part slightly to create a temporary aisle. This “movable rack” concept, combined with gantry-based retrieval, yields a storage density that static racking cannot match. For a given warehouse footprint, the Herochu ASRS stores up to 3.5 times more linear meters of long goods.

Speed as a Key Performance Indicator

In any ASRS, the system’s throughput is directly proportional to its speed. The Herochu gantry achieves a maximum travel speed of 50 m/min—double that of competing gantry systems (which typically run at 25 m/min). When processing a sequence of storage and retrieval commands, this speed difference accumulates quickly. For example, a facility performing 200 dual cycles (store and retrieve) per day, with an average gantry travel distance of 30 meters per cycle, would see 6,000 meters of travel per day. At 50 m/min, that travel consumes 120 minutes; at 25 m/min, it consumes 240 minutes. The faster speed effectively doubles the ASRS’s throughput capacity without increasing the number of gantries. Lifting speed is also important: 5-15 m/min, adjustable based on load weight and fragility.

Component Quality for 24/7 Operation

An ASRS is typically expected to run continuously across multiple shifts. Component failures cause production stoppages. Herochu therefore sources only premium-grade components. The operator interface is a Siemens touchscreen, chosen for its industrial durability and intuitive layout. Omron sensors—including photoelectric, inductive, and laser types—provide feedback for positioning, load detection, and collision avoidance. Schneider Electric supplies the motor controls, contactors, and circuit protection. These brands are globally recognized for reliability. Additionally, the gantry’s structural frame is produced using column gantry milling machine precision machining, ensuring that the rails and drive components remain aligned for years. External sheet metal covers protect all sensitive electronics from dust and impact.

Automatic Weighing, Balance Management, and Library Swapping

Three advanced features distinguish the Herochu Gantry-Based Long Goods ASRS from simpler systems. First, automatic weighing is integrated into the loading platform. Every time the gantry picks a material bundle, the system records its weight. This data feeds into inventory management, enabling weight-based cycle counting and verification against shipping documents. Second, balance management algorithms continuously monitor the distribution of weight across all shelf towers. If a tower becomes overloaded on one side, the WMS will assign new storage locations to rebalance the system. Third, library swapping allows operators to exchange entire shelf modules. For seasonal products, the library swapping feature can move an entire set of shelves containing winter-grade materials to a more accessible location while relegating summer stock to a higher level. All three features are controlled through the Siemens HMI with just a few touches.

Seamless WMS/WCS Integration

The software backbone of the Herochu ASRS consists of the in-house developed Warehouse Management System (WMS) and Warehouse Control System (WCS). The WMS maintains a real-time digital twin: every shelf location is mapped, every stored item is tracked by SKU, lot number, and remaining length. The WCS is the real-time executor: it receives commands from the WMS, computes optimal paths for the gantry, and manages acceleration profiles to minimize load swing. Large-screen displays can be configured to show warehouse-wide occupancy, pending orders, and gantry status. For integration with enterprise systems, Herochu provides REST APIs and database connectors. The result is an ASRS that fits seamlessly into Industry 4.0 architectures.

Technical Parameters for Various Lengths and Loads

The Herochu Gantry-Based Long Goods ASRS is offered in three standard configurations, with custom designs available for nonstandard lengths. Model HC-X6053-8: maximum pipe/profile length 6,000 mm; number of layers 5 (customizable); max load per level 3,000 kg; number of racks 8 (customizable). Model HC-X7065-10: length 7,000 mm; layers 6; load per level 5,000 kg; racks 10. Model HC-X8085-10: length 8,000 mm; layers 8; load per level 5,000 kg; racks 10. Gantry traveling speed adjustable 5-30 m/min; gantry lifting speed 5-15 m/min; repeatability ±2 mm. All models operate on a standard 380V/50Hz or 480V/60Hz electrical supply, with power consumption depending on load and frequency of use.

Loading Platform with Automatic Centering

One common failure point in long goods ASRS is misalignment during loading. If the material bundle is not centered, the gantry’s gripper may engage it off-balance, leading to unstable lifting or even dropped loads. The Herochu system includes a motorized automatic centering mechanism on the loading platform. As the bundle rests on the platform, side pushers activate, pressing the bundle until the center of mass aligns with the gantry’s pick axis. Optical sensors verify final alignment before the gantry moves. This feature alone reduces load drop incidents by an estimated 90% compared to manually centered systems. For operators, it means less time spent adjusting loads and more confidence in the ASRS’s reliability.

Case Study: Steel Service Center Transformation

A Midwest steel service center stored round bars from 4,000 mm to 7,500 mm in static floor racks. The racks occupied 80% of the warehouse, leaving little room for processing equipment. Daily inventory counts were impossible because workers could not easily access bars buried at the back of racks. After installing the Herochu HC-X8085-10 gantry-based ASRS, the service center reduced its storage footprint to 35% of the previous area. The freed space was converted into a new cutting line and finished goods staging area. Inventory accuracy improved from approximately 75% to 99.5% because the WMS tracked every bar by its unique ID. The gantry’s 50 m/min travel speed allowed the service center to process customer orders in an average of 3 minutes per line item, down from 12 minutes previously. The system paid for itself in 18 months through labor savings, reduced inventory carrying costs, and increased sales capacity.

Safety, Maintenance, and Support

Herochu has designed the gantry-based ASRS with multiple safety layers. Light curtains at the entry points to the storage area detect personnel and halt gantry motion. Emergency stop cords run along the entire length of the gantry’s travel. All exposed moving parts are enclosed by protective sheet metal. Routine maintenance involves cleaning the Omron sensors, lubricating the gantry’s linear guides, and checking the tension of the drive belts (or chains, depending on configuration). The Siemens HMI provides maintenance reminders and stores a log of all error events. Herochu offers a one-year warranty on all components, with extended service contracts available. Remote diagnostics via the WCS software allow Herochu engineers to troubleshoot most issues without a site visit, minimizing downtime.

Conclusion: The Future of Long Goods Storage

As manufacturing and distribution facilities seek higher efficiency from existing real estate, the demand for ASRS solutions tailored to long goods will grow. The Herochu Gantry-Based Long Goods ASRS meets this demand with proven technology: high-speed gantry, mobile shelf towers, premium automation components, and integrated software. Whether the application is steel bars, aluminum tubes, plastic pipes, or composite profiles, Herochu delivers a system that maximizes space utilization, eliminates manual retrieval errors, and provides real-time inventory visibility. For any operation serious about modernizing its long goods storage, the Herochu gantry-based ASRS is the definitive solution.