Fully Automatic Storage and Retrieval Systems for Laser Cutting Machines

The term “lights-out manufacturing” has moved from aspirational to achievable, particularly in sheet metal cutting. Fully automatic storage and retrieval systems for laser cutting machines represent the pinnacle of this evolution. Herochu has developed a generation of AS/RS (automated storage and retrieval systems) that do more than just hold sheets—they actively manage material flow, communicate with cutting machines, and enable continuous operation without human intervention. Unlike basic material handling setups that still require occasional operator input, Herochu’s fully automatic systems eliminate manual touchpoints entirely, from raw sheet receipt to finished part removal.

At the heart of these systems is a storage and retrieval machine (SRM) that travels vertically and horizontally within one or more storage towers. Each tower consists of multiple bays, each bay holding a pallet or directly supporting sheet stacks. The SRM uses telescopic forks or suction-based extractors to retrieve a specific sheet and deliver it to a load station adjacent to the laser cutter. After cutting, the same SRM can remove the entire cut sheet (still on the cutting table’s pallet) and transfer it to an unload station, where a separate shuttle or conveyor takes over. The key differentiator of Herochu’s fully automatic storage and retrieval systems is the optional rail system that allows a single SRM to service multiple towers and multiple cutting machines. This rail-guided configuration transforms a linear arrangement into a flexible material distribution network.

Consider a typical factory layout with two fiber laser cutters of different bed sizes, one plasma/laser combination machine, and an oxyfuel cutter for thick plates. Without automation, each machine requires dedicated operators and forklift support. With Herochu’s fully automatic system, a single SRM on a rail can reach all four machines. The software receives production orders, checks available sheet inventory in the towers, and schedules retrieval sequences. When Machine A finishes its job, the SRM automatically delivers the next plate for Machine A while simultaneously picking up finished parts from Machine B’s unload station. The system tracks partial plates across multiple machines. For example, a 4’x8’ sheet may be partially cut on the fiber laser, then later the same remnant is retrieved for a small part on the oxyfuel machine. The SRM handles this seamlessly.

Productivity data from Herochu customers using fully automatic storage and retrieval systems is striking. One heavy equipment manufacturer reported a 95% reduction in machine idle time related to material handling. Their previous operation averaged 22 minutes of waiting per hour while operators located plates, flagged down a forklift, and manually positioned sheets. After installing a Herochu system with two towers and a rail-guided SRM serving three lasers, idle time dropped to less than two minutes per hour. Overall throughput increased by 112% without adding any cutting machines. The manufacturer now runs 24 hours per day on weekdays and 16 hours on weekends, with only a single technician monitoring the system remotely.

Another advantage of fully automatic systems is their ability to handle partially cut plates intelligently. In many job shops, a sheet that has been partially cut is either scrapped or set aside in a “remnant pile” that is rarely used again. Herochu’s storage and retrieval system treats partial plates as valuable assets. After a cutting job, the system scans the remaining material on the pallet, updates the inventory database with the exact dimensions and usable area, and returns the partial plate to a designated bay. When a future nesting job can fit on that remnant, the system automatically selects it instead of a full sheet. This capability can reduce raw material consumption by 10–20% annually, a significant saving given volatile steel prices.

The software that drives Herochu’s fully automatic storage and retrieval systems for laser cutting machines is built on a real-time control architecture. It interfaces directly with the laser’s CNC and nesting software. When a nesting file is generated, the software checks available sheet inventory and assigns the most material-efficient sheet. If the required sheet is not in the tower, the system queues a request for manual loading (or integration with an external warehouse management system). During production, the software monitors cutting progress and pre-stages the next sheet so that when the current job finishes, the sheet exchange takes less than 90 seconds. For lights-out operation, the system can be configured to send alerts via SMS or email if consumables (like nozzles or lenses) need attention, but otherwise runs autonomously.

Configuration flexibility is another hallmark of Herochu’s approach. Towers can be built to any height, limited only by building clearance, with typical capacities ranging from 20 to 150 tons of stored material. The SRM’s travel speed is adjustable; high-speed configurations achieve 120 meters per minute horizontal and 60 meters per minute vertical. For heavy plates up to 20 mm thickness, the retrieval forks are reinforced with hardened steel guides. For thin, flexible sheets (0.5–2 mm), suction-based extractors with blow-off nozzles prevent double-pickup. The rail system can extend up to 100 meters, connecting multiple towers and machines in a linear or L-shaped layout. Turntables are also available for non-linear arrangements, allowing a single SRM to service machines arranged in a U-shaped production cell.

Safety and reliability are engineered into every component. The SRM includes redundant encoders to verify position accuracy within ±1 mm. Light curtains and pressure-sensitive floor mats stop all motion if an operator enters the travel zone. The vacuum system for sheet handling includes a reserve tank; if power fails, the suction holds for 30 seconds, allowing the sheet to be lowered safely. Herochu’s fully automatic systems comply with ISO 13849 safety standards and CE marking requirements. Regular audits by third-party safety inspectors are available as part of a service contract.

For companies considering this level of automation, Herochu recommends a phased approach. The first phase involves installing a single tower and SRM serving the busiest laser cutter. After three to six months of operational data, a second tower is added, then a rail system, and finally integration with additional machines. This phased deployment spreads capital expenditure and allows operators to build confidence gradually. Herochu provides turnkey installation, including foundation design, electrical integration, and software configuration. Training for maintenance staff covers mechanical adjustments, sensor calibration, and software diagnostics.

In conclusion, fully automatic storage and retrieval systems for laser cutting machines from Herochu deliver more than material handling—they enable a fundamental shift in production strategy. The combination of rail-guided SRMs, intelligent remnant management, multi-machine support, and 24/7 autonomous operation allows fabricators to cut parts while the building is empty. Productivity increases of 90% or higher are not theoretical; they are documented results from Herochu installations worldwide. For any metal fabricator seeking to maximize laser utilization, eliminate manual handling variability, and reduce per-part costs, Herochu’s fully automatic systems represent the benchmark solution.