The automation of long goods storage has historically lagged behind other warehouse functions. The dimensions and weight of tubes, bars, and profiles present challenges that conventional automated storage and retrieval systems are not designed to address. Standard ASRS solutions, optimized for palletized or case goods, lack the structural capacity, handling precision, and spatial configuration required for efficient tube storage. Herochu has bridged this gap with the Automatic Tubing Storage Racking System, a rail-guided, gantry-served ASRS that delivers unprecedented efficiency in tube and bar warehousing.
The Honeycomb Advantage: Density Without Compromise
The Herochu tubing storage system employs a honeycomb racking architecture that maximizes storage density while maintaining individual bundle accessibility. Unlike conventional cantilever racks, where arms extend from vertical columns and create fixed storage positions, the honeycomb configuration arranges storage cells in a grid pattern that can be densely packed without sacrificing retrieval speed. Each cell is sized to accommodate a specific tube or bar bundle, with the cell dimensions matched to the material’s diameter and length.
This honeycomb approach delivers two critical advantages. First, it eliminates the wasted space between cantilever arms that occurs when storing materials of varying diameters—each cell is sized precisely for its contents, minimizing void space. Second, it enables the gantry system to access any cell directly, without the need to reposition or relocate adjacent bundles. The result is a storage system that combines the density of bulk stacking with the accessibility of individual racking.
Gantry-Served Automation: Precision Retrieval on Demand
The Herochu tubing storage system integrates a high-speed gantry retrieval mechanism that serves the honeycomb racking array. The gantry travels along floor-mounted linear guide rails, positioning itself precisely at the target storage cell. A vertical lifting platform descends to the appropriate level, engages the material frame, and retrieves the requested tube or bar bundle. The entire operation is executed under PLC control, with positioning repeatability of ±2 mm ensuring accurate engagement every time.
The system’s operational parameters are optimized for tube and bar handling. Horizontal travel speeds reach 30 meters per minute, while vertical lifting operates at 9 meters per minute. These speeds, combined with the direct-access honeycomb configuration, enable rapid retrieval cycles that keep pace with production demands. For a facility operating a high-speed tube laser cutter or a just-in-time fabrication cell, this responsiveness translates directly to increased throughput and reduced work-in-progress inventory.
Heavy-Duty Engineering for Industrial Loads
Tubes and bars are dense materials, and their storage demands structural engineering that goes far beyond standard shelving. The Herochu tubing storage system is designed for heavy-duty industrial service, with each storage level supporting up to 3,000 kg and total system capacities reaching 500 tonnes. The main structure—columns, beams, and guide rails—is fabricated from structural steel and engineered to withstand the point loads and dynamic forces generated by gantry operation.
The chain drive transmission mechanism, selected over belt drives for its superior resistance to environmental factors, ensures reliable operation in the harsh conditions typical of industrial warehouses. Dust, metal shavings, temperature variations, and continuous operation all place demands on the drive system that chain drives are uniquely equipped to handle. This robust engineering ensures that the system delivers consistent performance over extended service life, with minimal maintenance requirements and maximum operational availability.
Smart Scalability and Customizable Configuration
No two tubing storage operations are identical, and Herochu has designed the Automatic Tubing Storage Racking System with configuration flexibility as a core principle. The number of storage towers, the number of levels per tower, the cell dimensions, and the overall system footprint are all customizable based on the customer’s specific inventory profile and facility layout.
The modular architecture enables phased implementation and future expansion. A facility can begin with a single storage tower and expand to multiple towers as inventory volumes grow. Additional levels can be added to existing towers, and the gantry travel envelope can be extended to accommodate new racking sections. This scalability ensures that the initial investment in automation continues to deliver returns as the business evolves, rather than becoming an obsolete constraint.
Integrated Safety Systems for Personnel and Equipment Protection
The handling of heavy tubes and bars carries inherent safety risks that Herochu has systematically addressed through integrated safety systems. Intelligent laser sensors continuously monitor the gantry’s working envelope, detecting personnel or obstructions and halting movement before contact can occur. Real-time load monitoring ensures that the gantry never attempts to lift beyond its rated capacity, preventing both equipment damage and potential load drops.
The physical design of the system further enhances safety. The gantry’s floor-mounted rail system distributes loads directly to the warehouse floor, eliminating the overhead rigging and suspended loads that characterize crane-based handling. Material frames cradle tubes and bars securely, preventing rolling and ensuring stable transport. And the automated retrieval process eliminates the need for personnel to work in proximity to suspended loads or maneuvering equipment.
Industry 4.0 Intelligence and Data Integration
The Herochu tubing storage system is a fully integrated Industry 4.0 solution, combining advanced control systems with real-time data management. The PLC and touchscreen interface provide intuitive control and comprehensive visibility into inventory status, system performance, and operational history. Operators can monitor stock levels, track material movements, and generate reports with a few screen taps.
Seamless ERP and MES integration extends this visibility to enterprise-level systems. Production planning can query available tubing inventory in real time, automatically triggering material issuance based on work order requirements. Inventory updates are automated with each storage and retrieval transaction, eliminating manual data entry and the errors it introduces. The result is a fully digital material management ecosystem where inventory data is always accurate, always accessible, and always actionable.
