Optimal Storage Rack Design for a 3D Compact AS/RS with Full Turnover-Based Storage

Compact, multi-deep (3D) automated storage and retrieval systems (AS/RS) are becoming increasingly popular for storing products with relatively low turnover on a compact area. An automated storage/retrieval crane takes care of movements in the horizontal and vertical direction in the rack, and a gravity conveying mechanism takes care of the depth movement. An important question is how to layout such systems to minimize the product storage and retrieval times. Although much attention has been paid to 2D AS/RS, multi-deep systems have hardly been studied. This paper studies the impact of system layout on crane travel time. We calculate the rack dimensions that minimize single-command cycle time under the full-turnover-based storage policy. We prove the expected travel time is minimized when the rack is square-in-time in horizontal and vertical directions and the conveyor’s dimension is the longest. We compare the model’s results with the performance of the random storage policy and show a significant crane travel time reduction can be obtained. We illustrate the findings of the study by applying them in a practical example.