ISD - Integrated Systems Design introduced the UltraStore Mini-Load ASRS, an automated tote and bin storage system that eliminates the single point of failure design inherent in traditional mini-load systems.
The new system uses off-the-shelf components and floor-surface operations to help reduce both capital investment and long-term maintenance costs.
The UltraStore Mini-Load ASRS delivers high-density storage and automated storage and retrieval without an embedded track. This design choice eliminates precision floor leveling requirements, accelerates installation, and provides system redundancy that keeps operations running during maintenance events.
"Traditional mini-load systems create dependencies that drive up costs and limit flexibility," says Tony Morgott, president of ISD - Integrated Systems Design. "The embedded track becomes a single point of failure. Proprietary components mean expensive spare parts and long lead times. We designed the UltraStore Mini-Load to solve these issues."
Key takeaways:
· The UltraStore Mini-Load ASRS uses a crane and aisle design that rides on the floor surface rather than embedded rail. This design change eliminates the largest factor in mini-load ASRS downtime. Crane redundancy means maintenance doesn't stop production. The UltraStore Mini-Load ASRS system is available with an extra crane for the system. If there is a need for maintenance or a problem with a crane in the system, users can simply push the Mini-Load crane out of the aisle and bring in the extra crane. The extra crane can be up and running in just minutes. In addition, organizations can utilize an attachment that attaches to one of their forklifts, and humans can make the picks while the primary crane is down. Either way, the mini-load is up and running in minutes.
· The system stores totes and bins in vertical racking structures up to 40 feet high. A crane per aisle retrieves items on demand and delivers them to picking stations, conveyors, or autonomous mobile robots. Multiple cranes can operate independently within the same system.
· The system uses commercial motion control platforms and standard automation hardware. Traditional mini-load systems often rely on proprietary components from overseas manufacturers.
· The system's industrial PLC architecture provides reliable control using automation platforms. Diagnostics identify issues before they cause downtime. Remote monitoring capabilities allow service teams to troubleshoot problems often without site visits. Otherwise, local service technicians are deployed.
· UltraStore Mini-Load adapts as operations evolve. Add storage aisles. Extend existing aisle length. Increase picking stations. The modular design accommodates growth without disrupting existing operations.
· UltraStore Mini-Load ASRS serves diverse applications, including e-commerce operations, manufacturers of store components for just-in-time delivery, electronics distributors, and automotive aftermarket suppliers.
· The system can handle up to 400-plus totes per hour, depending on configuration and size. Capacity scales from 500-5,000 storage positions.
