Logistics System by FAB Fördertechnik for Grieshaber Weingarten

FAB Fördertechnik und Anlagenbau GmbH from Waldshut-Tiengen implements a building-wide concept with a quickly dismountable conveyor bridge on behalf of GRIESHABER Logistik GmbH, Weingarten. The goal was to automatically and efficiently distribute goods from production to the various pickup points in the existing warehouse and the new building.

(Waldshut/Tiengen) The internationally operating logistics service provider GRIESHABER Logistik GmbH, headquartered in Weingarten, has invested in a new logistics center at the Cologne location, covering an area of nearly 8,900 square meters and with a capacity of approximately 9,600 CP3 pallets. GRIESHABER specializes in the design and implementation of individual logistics solutions for industrial and commercial customers. In the current project, the existing warehouse in the existing building was to be equipped with conveyor technology and connected to the new logistics center for a customer from the chemical industry.

The goal was to automatically and efficiently distribute goods from production to the various pickup points in the existing warehouse and the new building. The transport goods consist of CP3 chemical pallets made of wood or plastic with a maximum weight of 1,400 kg.

In close coordination with GRIESHABER Logistik GmbH, a suitable material flow concept was developed and implemented.

Goals of the Conveyor Concept

• Expansion of buffer capacity for the “breathing” of the entire system during different working hours in production and logistics.
• Integration of a second conveyor line from the existing warehouse towards the logistics center.
• Incorporation of an additional pallet retrieval in the new hall with destination management in the PLC for the two logistics halls.
• Bridging the gas pipeline area using a quickly dismountable conveyor bridge.

Initially, the existing outbound conveyor line was expanded with a turning device featuring an integrated shifting unit that takes over the function of direction selection. An additional inbound conveyor line with a loading station was installed parallel to the existing outbound conveyor line with a pickup point to also channel goods from here onto the new conveyor line into the logistics center.

Goods from production reach the turning device with the shifting unit via the existing conveyor line. Here, it is decided whether the pallets are transported straight into the logistics center or diverted to the right towards the outbound conveyor line of the existing warehouse. For this purpose, the pallets are equipped with barcodes, in which the respective destination is coded article-specifically. The management of the destinations is realized via a PLC control.

Towards the logistics center, the new approximately 110-meter-long roller conveyor line connects the existing building with the adjacent logistics building via a dismountable conveyor bridge.

Dismountable Conveyor Bridge

A special feature applies to the conveyor section between the existing and the new logistics building. Here, there is an approximately 8-meter-wide protective strip of a gas pipeline. In this area, a conveyor line that is easy to dismount was commissioned, designed in compliance with regulatory requirements. The conveyor bridge was executed as a covered steel structure with side cladding.

The overall 15-meter-long construction can be completely dismounted in an area of 8 meters with a low time expenditure of about 30 minutes using a forklift, should access to the gas line be required. Sectional doors are installed at the entrance and exit of the bridge, which automatically open and close as soon as goods pass through.

Buffer Capacity Provides Flexibility

To ensure maximum buffer capacity and to absorb fluctuations or disruptions, the entire conveyor line is designed for buffering the pallets. On the 4.5-meter-long roller conveyor elements, 3 pallets form a buffer with a maximum total weight of 4.5 tons.

The advantage of the buffer is particularly evident on weekends when finished goods from production are buffered on the conveyor line and can only be distributed to the warehouse or logistics area on Mondays. Then, up to 90 pallets can be made ready for pickup.

Reliable Control and Integrated Safety Concept

The control of the conveyor system is carried out via a safety PLC Siemens S7, with the networking of the system via Profinet. The FAB service team can access the system at any time via VPN. Manual operation is organized with a mobile panel distributed over 12 connection points along the conveyor system. Each drive is equipped with a Movimot and integrated into the bus system.

The system has been integrated into the existing safety concept. Along the conveyor line, 2 crossings have been established, secured by light barriers, allowing employees to cross safely if necessary.

To keep the downtime of the existing system as short as possible, the implementation was carried out in 2 construction phases. The assembly of the complex system was conducted during ongoing operations. With the commissioning, the project was successfully completed and handed over to the client.

“The project duration from the planning phase to realization and commissioning on site was only 6 months. Due to the well-thought-out concept from FAB and the close and effective coordination with all involved trades, a smooth project process was ensured,” says Gregor Schnell, Managing Director of Grieshaber Logistik Weingarten.

To maintain the performance and availability of the system in the future, annual maintenance and UVV inspections are carried out by the FAB service personnel. Through a VPN connection to the control system, a current view of the system is always possible. Additionally, direct intervention can also be made quickly and easily if needed.

Components

150 m roller conveyor – 1 turning device with shifting unit – 1 conveyor bridge – 2 sectional doors – 1 fire protection door – 1 impact protection – 2 crossings

Photo: © FAB