Mini-Load AS/RS Part Storage System

Prosimtech Engineering has developed a Mini-Load AS/RS (Automated Storage and Retrieval System) solution that ensures precise, secure, and fully automated management of specialized parts and components used in production facilities.
This system provides a high-tech hardware and control infrastructure for fast, accurate, and traceable retrieval, storage, and return of small-volume materials.

System Description

The Mini-Load AS/RS system is a warehouse automation solution designed for the precise, automated, and high-speed handling of materials.

Key components include:

• Storage Racks: Custom steel structures up to 7 meters in height

• Robot Crane (Stacker Crane): Automated carrier that picks and places materials on the racks

• P&D (Pick-up & Deposit) Stations: Input/output points where materials are delivered to or retrieved from the system

• Control System: Prosimtech’s WMS-based automation infrastructure manages the robot crane, conveyors, and sensor network

This configuration enables a fully unmanned, low-error, and highly accurate storage solution.

Mini-Load AS/RS Features

• Material Types: Boxes of 300×140×400 mm, 300×280×400 mm, 400×280×600 mm

• Rack Dimensions: 1000×6500×45700 mm

• Warehouse Height: 7 meters

• Capacity: 2,000+ storage locations

• Conveying System: Servo-controlled mini crane + static P&D stations

• Station Type: Static (fixed rack-connected) P&D structure

• Control Infrastructure: Siemens S7-1500 PLC + Profinet

• Software Infrastructure: Prosimtech WMS (Warehouse Management System)

• Energy System: Regenerative servo-driven motors

Operating Principle

1. The operator places or retrieves material at the static P&D station.

2. The robot crane detects the box via sensors and stores it on the appropriate rack.

3. The system automatically records the storage address of each item.

4. Upon request, the robot crane retrieves the box and delivers it to the designated P&D station.

5. The operator picks the part, and the box is automatically returned to its rack.

This cycle is completed in seconds, providing high-speed operation with minimal errors.

System Advantages

• High accuracy in small-part management

• 100% traceability and digital inventory tracking

• Fully automated flow following FIFO principles

• Saves labor and time

• Secure storage of critical parts

• Operator-free, ergonomic, and safe operation

• Low maintenance and high system continuity

The Mini-Load AS/RS system is ideal for production and logistics environments where secure storage of specialized parts is critical. It efficiently utilizes warehouse heights of up to 7 meters, maximizing storage space and operational efficiency.

Prosimtech Engineering Contribution

Prosimtech Engineering developed all mechanical, electrical, and software components in-house, including:

• 3D mechanical and rack design

• Servo-controlled mini crane manufacturing

• P&D station integration

• WMS and automation synchronization

• Testing, commissioning, and operator training

The project was implemented with a fully domestic design and control infrastructure, providing a scalable automated storage solution suitable for production lines and warehouse operations across different industries.