3D shuttle storage system without central lifts: one less component, countless benefits more

The autonomous shuttle — powerful, low-maintenance, scalable

The shuttle is at the heart of advasolutions' automated warehouse system. It handles both horizontal transport and vertical level changes — completely without central warehouse lifts. While conventional systems rely on central stacker cranes, advasolutions replaces them with flexible, autonomous shuttles: The shuttle is able to turn its drive wheel 90 degrees, thread it into a rack on the climber and climb up or down independently. A single motor controls all directions of movement, which reduces mechanical complexity, sustainably reduces total operating costs and avoids bottlenecks and central dependencies.

The shuttles are controlled centrally via the warehouse management system, which intelligently coordinates orders, routes and priorities. At the same time, vehicle sensors detect obstacles and faults and can therefore react to them.

Batteries with a running time of three to four hours ensure energy supply. If the charge level is too low, the shuttle goes to the designated station, where the battery is changed fully automatically in a very short time. The orders placed during this time are automatically taken over by other cars, so that operations remain uninterrupted.

Our system is also convincing when servicing is required: If a shuttle fails, it can be removed and replaced by personnel without special tools or expert knowledge. With remote access, advasolutions provides direct support when required, so that no on-site deployment is necessary.

With a load capacity of up to 20 kg, the shuttles transport a wide variety of articles with product dimensions of up to 800 × 400 × 600 mm [Tv1] without standardized system containers. Cardboard and individual items can also be stored directly. For temperature-sensitive applications, the vehicles can be cooled down to 3 °C.

For you, this means that you benefit from a highly available, low-maintenance system that minimizes failure risks and can be flexibly scaled. Additional shuttles can be integrated temporarily and without major modifications to absorb power peaks. This increases process reliability, reduces operating costs and ensures economical and future-proof warehouse structures.

The rack in the shuttle warehouse — more than just a standardized shelving system

The rack forms the basic framework of our 3D shuttle storage system. It fulfills two central functions: On the one hand, it carries the warehouse shelves in which the articles are stored. On the other hand, it integrates the tracks on which the shuttles move. The robust steel construction is modular, is precisely adapted to the spatial conditions and can be extended at any time as required.

A central element within the rack structure is the so-called climber: a vertical passage with a rack that allows the shuttles to switch between levels using their own drive.

By specifically scheduling one or more climbers — at the front and back of the rack or additionally within the structure — traffic flows in the warehouse can be significantly accelerated. The system not only increases throughput, but also throughput per square meter: Several transport units can operate on the same route at the same time without blocking each other.

The advasolutions rack system not only creates maximum stability, but also supports the free movement of the shuttles in three-dimensional space. Thanks to modular expandability, flexible integration of increases and precise planning, the performance of your warehouse can be tailored exactly to your requirements — whether more storage space, higher speed or a combination of both. This allows you to expand your storage capacity in a targeted manner and adapt it to changing requirements

The shelf — dynamic, space-efficient, product-flexible

The actual storage takes place on the shelf: Instead of rigid storage spaces with fixed container sizes, it works with dynamic storage spaces that adapt individually to the shape and size of the stored products. Cardboard boxes, individual items or bulky items are stored directly. Pallet goods can also be stored directly if required, without additional repackaging. The system exactly blocks the required area — no more, no less.

Each shelf supports a load of up to 200 kg, while the deflection remains below 5 mm — even with heavy or unevenly distributed items. Different height distances allow fine-tuned use of space, which is individually adapted to your range of products.

As soon as an item is removed, the system registers the vacant space and automatically reallocates it. This creates a highly flexible warehouse layout that is constantly being optimized.

With the dynamic shelf structure, you can maximize your storage density, reduce empty space and integrate a wide variety of product types without repackaging or system containers. This saves space, increases storage capacity, reduces costs and creates maximum flexibility — even with a growing variety of articles.