Automated Storage System for Metal Sheet with Loading and Unloading

Many automated storage systems excel at retrieving raw sheets and delivering them to a machine. Fewer can handle the reverse flow – removing finished parts, storing remnants, and disposing of skeletons. Herochu closes this loop with the automated storage system for metal sheet with loading and unloading capabilities integrated into a single tower. This is not a storage rack with a separate unloader bolted on. It is a purpose-built AS/RS (Automated Storage and Retrieval System) designed from the ground up to manage bidirectional material flow between shelves and production equipment.

The Herochu Full-Line AS/RS series, led by the HC-A6015-HD (heavy-duty variant), handles sheet sizes up to 6,000 mm × 1,500 mm with per-shelf loads of 5 tonnes. Unloading capacity matches loading capacity: the same telescopic fork that picks raw sheets from shelves can place finished parts onto designated pallets within the storage matrix. This symmetry enables true lights-out manufacturing, where raw stock enters the system at shift start and cut parts exit only when an operator retrieves the finished pallet hours later.

Bidirectional Material Flow: Engineering for Unloading

Most automated storage systems treat unloading as an afterthought – an optional conveyor at the machine exit that pushes parts into a bin. Herochu’s design philosophy differs: if the system can pick a sheet from a shelf and place it on the cutting table, it can also pick parts from the cutting table and place them on a shelf. The hardware is identical; only the control logic changes.

In operation, the automated storage system for metal sheet with loading and unloading executes a typical cycle as follows:

1. Loading phase: The telescopic fork retrieves a raw sheet from Shelf A, transports it to the cutting table, and retracts.

2. Cutting phase: The laser cuts parts according to the NC program.

3. Unloading phase: After cutting, the fork extends onto the cutting table. Vacuum cups or magnetic grippers (selectable based on part thickness and material) lift finished parts. The fork retracts, and the carriage moves to an empty shelf or a dedicated “parts out” pallet.

4. Skeleton disposal: The fork makes a second pass to collect the remaining skeleton. Rather than storing it, the system drops the skeleton into a floor-level bin integrated into the base of the AS/RS.

5. Remnant storage (optional): If partial sheets remain that are large enough for future jobs, the system can return them to a designated remnant shelf, updating inventory automatically.

This bidirectional capability reduces operator intervention by 80–90 % compared to systems that require manual unloading.

Technical Architecture for High-Volume Unloading

The HC-A6015-HD automated storage system uses dual vacuum circuits: one for raw sheet pickup (high flow, rapid grip) and one for finished part pickup (lower flow, gentle grip to avoid bending thin parts). Switching between circuits is automated based on the job’s data record from the MES. For magnetic materials (mild steel), permanent electromagnets can be fitted to the fork, eliminating compressed air consumption entirely – a valuable option for shops without clean dry air lines.

Maximum unload weight per cycle is 200 kg, same as load capacity. However, the system can make multiple unloading passes if a single cutting table output contains dozens of small parts. The control software uses a nesting map to know the position of each part, enabling selective pickup – for example, retrieving only parts from the left side of the table first, then returning for right-side parts.

Storage floors remain 8 to 13, but the heavy-duty variant adds reinforced shelf beams to handle the dynamic forces of both loading and unloading at full speed (12 m/min horizontal). A shock-absorbing buffer at the end of each fork extension prevents part slippage during rapid deceleration.

ERP Integration and Work Order Sequencing

Herochu’s automated storage system does not merely react to commands – it predicts them. By connecting to your ERP via REST API or SQL database polling, the system looks ahead to upcoming work orders. If the next three jobs require 2 mm HR steel, 1.5 mm galvannealed, and 4 mm aluminum, the AS/RS will pre-position those sheets on shelves closest to the outlet port, reducing carriage travel time. This “intelligent staging” cuts average load time from 25 seconds to 12 seconds for sequenced jobs.

For unloading, the system can sort parts by destination. Work order #101’s parts go to Shelf B2; work order #102’s parts go to Shelf C5. The operator later retrieves entire pallets, not loose piles. Barcode labels printed by the system and affixed to each pallet ensure downstream traceability.

Safety Features Specific to Unloading Operations

Unloading presents unique hazards: parts may have sharp edges, thin parts may curl, and small parts may be missed by vacuum cups. Herochu addresses these with:
– Edge detection sensors on the fork that confirm the part is fully gripped before retracting.
– Curled sheet compensation – adjustable vacuum cup compliance that accommodates up to 8 mm of bow in a thin sheet.
– Part presence verification using through-beam lasers after pickup, preventing false “empty shelf” errors.
– Operator interlock that prevents fork extension if the cutting machine’s protective door is open.

The 360° LED status lighting changes color during unloading (blue) versus loading (green), providing intuitive visual feedback to floor personnel.

Scalability to Full Automation Lines

A single automated storage system for metal sheet with loading and unloading can feed not only laser cutters but also:

• Herochu Compact Tower for additional sheet capacity

• Robotic press brake bending cells (via conveyor handoff)

• Automated welding stations

When integrated with Herochu’s MES software, the complete cutting-to-bending line runs 24 hours a day with no operator fatigue. The AS/RS becomes the central nervous system, tracking every kilogram of steel from incoming storage to finished component.

Conclusion: Closing the Material Loop

Herochu’s Full-Line AS/RS redefines what an automated storage system can do. It is not a passive warehouse – it is an active participant in production, loading raw stock and unloading finished parts with equal precision. For fabricators aiming to eliminate manual handling entirely, the automated storage system for metal sheet with loading and unloading from Herochu is the missing link between digital planning and physical throughput.