Fully Automatic Sheet Material Storage – PLC Touch Screen Control with Automatic Weight Detection for Zero-Touch Operation

Fully automatic sheet material storage is no longer a luxury reserved for automotive giants. Herochu delivers a complete Fully Automatic Sheet Material Storage solution that operates without constant human intervention. From the moment a sheet enters the system until it leaves for production, every action – weight detection, location assignment, retrieval, and dispatch – happens automatically. The only manual tasks are loading plates onto the inlet station and removing them at the outlet. Everything else is PLC-driven.

How Herochu Eliminates Manual Handling

Conventional sheet storage requires operators to measure each plate, record its location on paper or a spreadsheet, and later search for it when needed. This process introduces errors, delays, and physical strain. Herochu’s fully automatic system uses a combination of sensors and motor drives to remove these pain points.

1. Automatic weight detection: Load cells under the inlet station measure each plate to ±0.5% accuracy. The PLC logs weight against a unique time stamp and position number.

2. Automatic storage: The system calculates the shortest travel path to an empty slot that matches the plate’s weight class and dimensions. The extractor moves horizontally and vertically to deposit the plate. No operator controls are needed during this cycle.

3. Automatic delivery: When a production machine requests a specific plate (by job number or material code), the PLC retrieves it without manual search. The outlet station presents the plate at a comfortable working height.

Touch Screen Control for Transparency and Override

The 15-inch industrial touch screen serves as the command center. It displays a color-coded warehouse map showing occupied slots (red), empty slots (green), and plates reserved for production (yellow). Operators can perform five main functions:

• Manual storage: Override automatic assignment and choose a specific slot.

• Manual retrieval: Extract any plate by entering its slot number.

• Inventory inquiry: Search by date, weight range, or custom tag.

• Maintenance mode: Disable certain zones for repair work.

• Report generation: Export daily activity logs via USB or network.

The interface supports multiple languages and includes animated diagrams showing extractor position in real time.

Safe and Efficient Heavy Load Bearing

Herochu engineers the structure for continuous heavy duty. Each layer handles 3T or 5T uniformly distributed load. The main frame uses welded H-beam steel with anti-corrosion paint. Linear guide rails are hardened and ground, with recirculating ball bearings rated for 10,000 operating hours between replacements. The chain drive incorporates automatic oilers that lubricate during every vertical movement.

Safety devices include:

• Overload protection (PLC cuts power if motor current exceeds 110% of nominal)

• Upper and lower limit switches on vertical axis

• End-of-travel limit switches on horizontal axis

• Emergency stop buttons at inlet, outlet, and control panel

• Light curtain at operator access points

Two Loading Modes Maintain Flexibility

Even fully automatic systems need to accommodate different upstream processes. Herochu retains the dual loading mode – forklift and overhead crane – so your material handling equipment does not need to change. The inlet station design includes fork pockets for pallet jacks or forklifts, plus lifting eyes for crane slings. For thin sheets that tend to bend, optional magnetic or vacuum lift assists can be integrated.

Performance Metrics from Actual Installations

These results come from a stainless steel processor handling 300 tons per week. The company reported full ROI in 14 months, driven by labor savings and reduced material damage.

Application Scenarios for Fully Automatic Sheet Material Storage

• Laser cutting job shops: Store common sheet sizes and automatically deliver to the cutting table based on nesting software output.

• Automotive stamping plants: Buffer large coils cut into blanks and feed press lines on demand.

• Shipyard plate yards: Organize thick plates by grade and thickness, eliminating crane waiting time.

• Metal distribution centers: Provide fast retrieval for customer pickup or truck loading.

Why Herochu for Fully Automatic Operation

Herochu has deployed over 150 fully automatic sheet material storage systems across Asia, Europe, and North America. Each system undergoes a 72-hour burn-in test at the factory, simulating peak load cycles. The company supplies complete documentation including electrical schematics, PLC ladder logic printouts, and maintenance schedules. Remote support is available via VPN connection to the touch screen panel. For facilities ready to move from ground piles to fully automatic storage, Herochu provides a turnkey installation including foundation work, rack assembly, and operator training. Request a site survey to determine the optimal number of floors and load rating for your sheet material portfolio.