Automated warehouse with satellite shuttle system
Challenge
Danieli Officine Meccaniche had to manage a very precise logistical challenge:
- large volumes of steel coils (~3 tons each)
- variable diameters with tight dimensional tolerances
- within a fixed footprint: ~6,150 m² and 14 m maximum height
- ensuring flow continuity up to ~60 coils/hour for at least 48 consecutive hours
- maintaining precision and cycle stability without performance degradation
- operating in a demanding steelmaking environment with coils exiting production up to 200°C
In short: the challenge was not only “how much”, but “how consistently”.
High density + service continuity + geometric control of high-weight UDCs.
Solution
To guarantee automatic handling of high-weight coils, an architecture with automatic stacker cranes equipped with satellite shuttle was selected, capable of operating in multi-depth while maintaining trajectory accuracy with different coil diameters.
Modulblok engineered a high-density automatic coil warehouse where:
- coils are stored on beams equipped with inclined tubes, dimensioned to accommodate different diameters
- the satellite shuttle handles UDCs in depth within the same aisle
Key design decision: unlike the traditional approach (increase guide thickness → more weight, higher inertia, higher CAPEX), Modulblok introduced a deep support tube to control guide deformation, preserve movement accuracy and ensure tight tolerances even under high loads and high temperatures.
Result: maximum storage density + dynamic stability of the automated system, without increasing structural CAPEX.
Technical highlights
- UDC: steel coil L = 2,400 mm, approx. 3 tons
- warehouse footprint ≈ 6,150 m²
- height 14 m
- beams + inclined tubes to accommodate different diameters
- PTFE (Teflon) support to withstand coils up to 200°C
- structural sample break tests → verification of real deformation behaviour
Benefits
- High storage density: ≈ 4,700 coils on ~6,150 m² at 14 m height in multi-depth layout
- Peak continuity: up to ~60 coils/hour for 48 h without performance degradation
- Precision & dynamic stability: deep support tube → reduced deflection, more accurate trajectories, fewer stops
- Higher safety: less manual handling of high-weight UDCs → more controlled, predictable processes
- CAPEX optimisation: “support tube” solution instead of thicker guides → lower costs with superior performance
