The transition from manual warehousing to automated material handling represents one of the most consequential operational shifts a manufacturing facility can undertake. Herochu has positioned itself at the forefront of this transformation with its Automatic Vertical Storage System—a fully autonomous, intelligent warehouse specifically engineered for pipes, tubes, and long profiles. This system combines heavy-duty mechanical engineering with cutting-edge software integration to deliver a storage solution that is as intelligent as it is robust.
PLC-Controlled Precision
At the heart of the Herochu Automatic Vertical Storage System is a sophisticated PLC control architecture that orchestrates every movement with millimeter precision. The PLC manages the gantry’s travel paths, coordinates loading and unloading sequences, and ensures that each storage and retrieval cycle executes flawlessly. Operators interact with the system through an intuitive Siemens touchscreen interface that displays real-time inventory data, storage location maps, and system diagnostics.
The touchscreen interface enables operators to execute automatic weighing of retrieved materials, manage load balance across multiple shelves, and perform library swapping—exchanging entire shelf modules—through intuitive on-screen menus. This level of control eliminates the guesswork that plagues manual pipe storage, where inventory counts are approximate and material locations are often forgotten.
Omron Sensors and Schneider Electric Components
Herochu equips its Automatic Vertical Storage System with industrial-grade components selected for reliability and longevity. Omron sensors provide precise end-stop and positioning feedback, ensuring that the gantry stops exactly where intended every time. Schneider Electric relays and circuit breakers ensure reliable power distribution, protecting the system from electrical anomalies that could cause downtime. This component selection guarantees long service life and minimal downtime, even in dusty or high-temperature environments typical of metalworking shops.
Fully Autonomous 24/7 Operations
The Herochu Automatic Vertical Storage System enables fully autonomous operations around the clock. High-speed, precision gantry technology delivers 24/7 unmanned storage and retrieval, slashing labor costs and eliminating handling errors. Facilities can run multiple shifts without requiring dedicated storage personnel—the system handles incoming materials, organizes them in the optimal storage location, and retrieves them on demand for production.
This autonomy extends to inventory management. Every bin, every bundle, and every move is recorded by the PLC and visible on the touchscreen the moment it happens. Warehouse managers can check stock levels, track material movements, and monitor system performance in real time, gaining complete visibility into their pipe inventory without walking the warehouse floor.
Industry 4.0 Integration
The Herochu Automatic Vertical Storage System is designed for seamless integration with existing enterprise systems. Advanced PLC and touchscreen control deliver real-time digital inventory tracking and enable bidirectional data exchange with ERP and MES platforms through API connectors. This connectivity ensures that inventory data flows automatically between the storage system and production planning software, eliminating manual double entry and reducing the risk of data errors.
The system’s Warehouse Management System (WMS) and Warehouse Control System (WCS) are fully self-developed by Herochu and supplied with every installation. The WMS handles inventory tracking, lot management, first-in-first-out (FIFO) assignment, and generates usage statistics. The WCS translates those commands into motion sequences for the gantry, optimizing travel paths to avoid collisions and minimize energy consumption. Both systems can display live stock levels on large production screens, enabling shop floor personnel to check material availability at a glance.
Digital Inventory Management with Real-Time Stock Display
Traditional pipe storage relies on manual counting and memory—methods that are inherently error-prone. The Herochu Automatic Vertical Storage System replaces these antiquated approaches with digital inventory management that displays real-time stock levels. Every pipe, bundle, and profile is tracked by material type, dimensions, and precise location within the storage tower. Operators can see the complete inventory status at a glance, eliminating the guesswork that leads to overordering, stockouts, and production delays.
Space Efficiency Through Vertical Design
The Herochu Automatic Vertical Storage System minimizes footprint through vertical design that exploits headroom conventional racks cannot reach. By scaling vertically rather than horizontally, the system achieves up to 80% space savings compared to traditional floor storage. This high-density, zero-aisle design reclaims valuable floor space for production equipment, assembly operations, or additional value-added activities. For facilities facing rising real estate costs or physical expansion constraints, the space efficiency of the Herochu system delivers immediate and measurable financial returns.
