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TGW Iberica, an automated logistics solutions supplier, uses Leuze Electronic products to position storage and retrieval units, transmit data and monitor safe pallet positioning at its new warehouse.

The company’s recently installed nine-lane, automatic, high-bay warehouse, which includes 6,600 pallet locations for storing food, operates in inhospitable ambient temperatures as low as -30C.

The 20m-high warehouse has a floor space of 40,000m and is divided into three temperature zones.

The first zone holds 3,400 storage locations, which are kept at a normal room temperature.

The second zone, the cooling area, is kept at 0C and holds 1,600 pallets, as does the third zone, the deep-freezing area, which has a temperature of -30C.

All of these locations are served by high-bay stacker cranes; to operate faultlessly in these extremely variable climatic conditions, these cranes must be equipped with a high-performance and reliable sensor system.

The cranes’ transportation paths are measured and positioned by two AMS 200 laser distance measuring devices from Leuze; one is used to control the driving movement, while the other is used to control the lifting movement.

To communicate between the stacker cranes and their base station, data is transmitted optically by Leuze’s DDLS 200 optical data transceivers, which operate with total immunity from the AMS 200 positioned alongside.

The company’s 46B series opto-electronic sensors monitor the positioning of the cargo throughout the warehouse.

The AMS200 absolute measurement systems (AMSs) are mounted in X and Y orientations at the same height as the running gear.

They offer several interface options and can internally calculate the absolute position of the high-bay crane and its lifting unit.

The speed of this calculation of position is key in enabling the high-bay crane to travel between locations at speed and in achieving TGW’s objective of offering a highly dynamic system.

Calibrated positions are reproduced with millimetre precision across an operating range of up to 200m; in addition, an absolute accuracy of +/-2mm is achieved.

The unit can also use the change of position against time to internally calculate velocity.

Thanks to the AMS200’s velocity feature, TGW Ibercia has seen a 30 per cent reduction in the complexity of mechanical velocity control mechanisms or buffers, which slow down the cranes from full speed.

Traverse paths for the cranes are divided into four different distance sectors, with each sector configured with a separate velocity.

The AMS monitors these parameters autonomously, reporting to control if the calibrated velocity is exceeded; this velocity control fulfils the requirement for a second independent measurement system, which is necessary for implementing this buffer reduction.

To ensure maximum system availability, the AMS200 issues early-warning messages, such as when its optics are becoming soiled or if the laser diode loses power, enabling timely preventative maintenance.

As an option, the optics of the AMS200s can come with integrated heating, enabling the units to work in the deep-freeze zone.

For communication between the stacker cranes and their base station, TGW Iberica uses Leuze’s DDLS 200 optical data transceivers.

The DDLS 200 system offers the benefit of high-speed data transmission without the wear issues of fixed wiring.

It is also said to be free from interference, unlike many wireless systems.

The transceivers use invisible infrared light, enabling them to be placed alongside the AMS200 optical distance measurement units.

The systems use laser red light to provide total immunity from each other.

The DDLS 200 system consists of a pair of devices that communicate bi-directionally, with each device operating as both a transmitter and a receiver unit using different frequencies.

The transceivers offer a variety of interface options, an operating range of up to 500m and total transparency.

Profibus masters do not need to be configured, saving commissioning time and cost.

The option of internal heating is also available on the DDLS 200 units and is used by TGW Iberica in the deep-freezing area to ensure trouble-free operation.

The AMS 200 and DDLS 200 systems offer additional functionality and features that simplify use and installation, according to Leuze.

Leuze Electronic

Leuze electronic the ‘sensor people’ are committed to being the supplier of choice by providing the best customer service and products.

Leuze electronic the ‘sensor people’ are committed to being the supplier of choice by providing the best customer service and products.

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