STOPA automatic storage systems as production hub

An automatic STOPA COMPACT II sheet metal storage system forms the basis of a future-oriented sheet metal factory at BINDER, a specialist in simulation cabinets. The aim is to maximize automation in and around the storage system, which acts as an internal logistics center. Among other things, the operator benefits from reproducible processes, high manufacturing quality and unmanned night shifts.

Thomas Luippold, Director of the COMPETENCE FACTORY of BINDER GmbH, Tuttlingen, which was founded in 1983, and his team have developed the concept of a future-proof automated sheet metal production. “The sheet metal storage system serves as the hub of our production. To link all process stages, we plan to connect all processing machines to the warehouse. We are therefore also planning further investments in driverless transport systems, because they are ideally suited for unmanned processes. In terms of production, the focus is on reproducibility of processes and consistently high quality. Apart from that, we want to minimize the skilled worker problem.”

According to BINDER, which claims to be the world’s largest specialist in simulation cabinets in which laboratories simulate biological, chemical and physical environmental conditions, end-to-end automation is essential. Regardless of the batch sizes. In order to realize the self-imposed quality standards, the company develops and manufactures exclusively in Germany. The 49-meter-long, 5.5-meter-wide and seven-meter-high automated warehouse from STOPA Anlagenbau GmbH, Achern-Gamshurst, was chosen because of its high performance, process reliability and cost-effectiveness. Since the system, which is used in three-shift operation and has 696 storage spaces, has been functioning as an in-house logistics center, it has been automatically supplying almost all the processing machines. The only exceptions are the manual transports to the press brakes, which the operator will also automate.

The automated warehouse has a sophisticated energy management system. The low energy consumption is due, for example, to a significant reduction in the weight of the storage and retrieval machine (SRM), which is based on two powerful, lighter drive motors and a more compact crossbeam. In addition, regenerative drive energy that occurs during braking and lowering can be used by providing the system directly to another drive as motor energy. Frank Heilemann, Head of Technical Services and Project Manager for the STOPA COMPACT II, appreciates these advantages. “We also use the optional back-feeding of the regenerative energy into the supply network, which would otherwise be lost as heat. Especially since we have invested in a state-of-the-art building, with the vision in mind that the plant will supply itself with energy.”

High throughput

The automatic STOPA COMPACT II sheet metal storage system acts as an internal logistics center at BINDER

A scissor lift table at the front, with storage stamps, pluggable stops for a coordinate corner, a pneumatic pallet locking device and a light barrier to monitor the maximum loading height, serves as a goods-in and goods-out station and as the starting point for the automatic processes. A patented weighing device integrated into the load crossbeam of the stacker crane provides BINDER with a high level of transparency with regard to the stored material. Lars Hoffmann, head of the sheet metal processing center, relies on the option of variable acceleration of the stacker crane. “For foiled and fully galvanized sheets, we set the values individually to prevent slipping. For non-slipping material or an unloaded stacker crane, we accelerate at maximum values. The result is greater process reliability and optimized cycle times.”

The RBG, which is equipped for loading heights of 90 and 275 millimeters, reaches speeds of 150 meters per minute when driving, 23 meters when lifting and 20 meters when pulling. To avoid collisions with stored material, it is equipped with an automatic loading height control that checks the spaces below and above the selected storage location. In addition, the RBG works with a contour control that monitors the correct position of the sheet metal package on the pallet during return storage. Two longitudinal scissor lift tables act as goods issue stations. Both are equipped with two fixed storage racks and light barriers to monitor the maximum loading height. In addition, there are energy supply lines up to 14 meters long, which are laid in underfloor channels. The screw-on covers of the channels can be driven over by forklifts with a load capacity of up to three tons.

Further scissor lift tables arranged along the sides supply punching machines with the help of automatic handling equipment. The scissor lift tables used as loading trolleys are equipped with the ‘last sheet detection’ function, a rotary encoder for positioned depositing or with spreading magnet equipment as required. The unloading trolley is equipped with a light barrier to monitor the maximum loading height and a rotary encoder. The operator buffers the punched parts in the warehouse until a subsequent process is due and a transport carriage automatically removes the parts. STOPA has installed a tandem change function to directly connect a bending cell to the system.

A real-time soft PLC integrated into an industrial PC controls the system components. The PLC communicates with the TRUMPF TruTops Fab Module Storage, which displays the material stocks and controls the material flow. Hoffmann emphasizes the wide range of sheet metal types in large, medium and small formats that BINDER stocks in the system, which has a high degree of space utilization. “We use only thin sheets. These include raw sheets, stainless steel, aluminum and electrolytically galvanized material. In addition to flat materials, we also store three-dimensional corrugated sheets.” The system, which operates with an availability of 98 percent, handles 50 sheet feeds to the punching machines, eight raw sheet storage operations, 46 deliveries to the bending machines and twelve retrievals to the bending cell every day.

Highlights of the solution

Sheet metal storage as an internal logistics center.
Maximum automation around the warehouse.
Reproducible production processes with consistently high quality.
Higher process reliability and optimized cycle times.
High throughput and cost-effectiveness.

Future-oriented design

In order to link all process stages, BINDER plans to connect all processing machines to the warehouse and to invest in driverless transport systems

In its early days, BINDER worked with a punching machine and a compact storage system. Today, the family-owned company with four branches and international sales partners delivers around 22,000 devices to companies, institutes and research facilities worldwide every year. The customers, who represent a wide range of industries, are located all over the world.

The decision to invest in the automated storage system was made as a result of the company’s continuous growth. STOPA was also chosen because the manufacturer has many years of experience with TRUMPF machines and therefore no interface problems are to be expected. Heilemann emphasizes the excellent cooperation, which had already put him in a confident mood during the project planning. “STOPA installed the sheet metal storage system in a short time from April to July 2017.”

Luippold, who expects the system to pay for itself in five to seven years, is optimistic about the future. “Thanks to the automation, the factory will be able to operate with a team of 25 to 30 people in the future. We designed the plant with foresight so that STOPA can extend the sheet metal storage system to up to 100 meters on our 8,000 square meter production area. The floor and other components are already designed for this. With this investment, we are helping to secure Germany as a production location.”

Picture: Frank Heilemann, Head of Technical Services and BINDER Project Manager for the STOPA COMPACT II, Thomas Luippold, Director of the COMPETENCE FACTORY, and Lars Hoffmann, Head of the Sheet Metal Processing Center (from left to right)

Frank Heilemann, Head of Technical Services and BINDER Project Manager for the STOPA COMPACT II, Thomas Luippold, Director of the COMPETENCE FACTORY, and Lars Hoffmann, Head of the Sheet Metal Processing Center (from left to right)

Author: Jürgen Warmbol