The transition from manual material handling to automated robotics represents one of the most significant productivity leaps available to modern fabrication shops. Herochu has engineered a comprehensive Robotic Sheet Metal Handling and Storage solution that integrates gantry robotics, automated storage, and intelligent controls into a unified system capable of supporting multiple laser cutting machines in synchronized, end-to-end automated processing. This system addresses the fundamental challenges of sheet metal handling: heavy loads, delicate surfaces, repetitive motion, and the relentless pressure to maximize machine utilization.
The Gantry Robot Architecture
At the core of Herochu’s robotic handling system is a heavy-duty gantry manipulator that traverses the storage tower and loading station with precision and power. The gantry structure supports transverse movement of the composite manipulator, enabling coverage of the entire storage and loading footprint.
The manipulator incorporates several advanced handling technologies:
- Vacuum suction system – Multiple oil-resistant vacuum cups provide secure gripping of sheet surfaces without causing damage or leaving marks.
- Hydraulic lifting mechanism – Synchronized hydraulic rams handle stacks up to 3 tons and delicate coated plates with equal ease.
- Fork opening and closing – Adjustable fork spacing accommodates varying sheet dimensions, with opening/closing speeds of 5 to 20 meters per minute.
This combination of technologies enables the robotic system to handle the full spectrum of sheet metal types: stainless steel, aluminum, mild steel, pre-coated blanks, and specialty alloys. The system handles sheets from 3000×1500 mm up to 6000×2500 mm, with maximum sheet weights of 500 kg per lift.
Synchronized Multi-Machine Operation
What distinguishes Herochu’s robotic handling system from simpler automation solutions is its ability to synchronize with multiple laser cutting machines simultaneously. The system coordinates material retrieval, loading, cutting, and unloading across multiple machines, creating a fully automated production center that operates with minimal human intervention.
This multi-machine synchronization delivers several operational advantages:
- End-to-end automation – Storage, handling, and loading/unloading are fully automated from raw material receipt to finished part staging.
- Continuous material flow – While one laser cutter is processing a sheet, the robotic system retrieves and stages the next sheet, eliminating machine idle time.
- Unified control – A single PLC control system governs all robotic and machine operations, ensuring coordinated activity across the production cell.
Integrated System Components
Herochu’s Robotic Sheet Metal Handling and Storage system comprises several integrated subsystems working in concert:
Material Warehouse Structure – The storage tower provides multi-tier storage capacity with adjustable layer spacing. Each tower accommodates up to 10 storage levels, with customizable configurations based on sheet dimensions and weight requirements.
Composite Loading/Unloading Manipulator – The primary function of this robotic subsystem is automated loading of raw materials and unloading of finished products. The manipulator handles the complete material flow from storage to machine and back.
Inbound/Outbound Storage System – This subsystem interfaces with conveyor vehicles to enable automated material transfer between the loading station and lifting position.
Finished Product AGV – Automated guided vehicles transport finished parts from the cutting station to downstream operations or finished goods storage.
PLC Control System – The central nervous system of the robotic handling solution, employing 15-inch touchscreen interface and Siemens PLC components for comprehensive control and monitoring.
Reducing Labor Costs and Improving Safety
The labor economics of Herochu’s robotic handling system are compelling. A single robotic manipulator can replace multiple forklift operators and material handlers, reducing labor costs while eliminating the physical strain and safety risks associated with manual heavy sheet handling.
Safety improvements extend beyond injury prevention. The robotic system operates with consistent precision, eliminating the handling errors that can damage expensive sheet materials or create production delays. Collision prevention and drop prevention systems ensure the safety of both operators and materials.
The system’s ability to operate unattended during night shifts further amplifies labor savings. Production can continue around the clock without overtime premiums or shift differentials, with the robotic handling system ensuring that laser cutters remain fed and finished parts properly staged.
Durable Construction for Industrial Environments
Robotic handling systems in fabrication environments must withstand demanding conditions: dust, vibration, temperature variation, and continuous operation. Herochu addresses these requirements through robust engineering and materials selection.
The storage tower features double-sided galvanized steel sheet construction (275g/m²) with hot-dip galvanized bolts, providing excellent corrosion resistance for long-term outdoor or indoor use. The gantry structure is engineered for rigidity and precision, with low-wear parallel cylinders ensuring reliability over millions of cycles.
The complete system meets CE, UE, and ISO 9001 certification standards, ensuring immediate acceptance in North American, European, and Australian markets.
