Table of contents
Floor................................................................................................. 6
Specifications for the floor....................................................................7
Height differences and evenness tolerances.......................................8
Racking.......................................................................................... 14
Assembly tolerances for racks and permissible deformations..........16
Safety distances in the rack................................................................18
Guide systems............................................................................... 19
Mechanical guide: rail guidance.........................................................20
a.) Design and assembly of guide rails...................................... 20
b.) Overview of rail types.......................................................... 22
Inductive wire guidance......................................................................24
a.) Laying an inductive guide wire............................................ 24
b.) Entering and exiting the aisle/changing aisles.................... 26
c.) Frequency generator............................................................. 27
Driver assistance system.............................................................. 28
1. Systems for determining vehicle position......................................29
a.) Magnets...................................................................................30
b.) Reflected light sensors............................................................31
c.) Bar code...................................................................................32
d.) RFID..........................................................................................32
2. Safety functions in the very narrow aisle......................................33
a.) End of aisle protection.......................................................... 33
b.) Height-dependent cut-off.......................................................34
c.) VNA navigation........................................................................35
Personnel protection systems...................................................... 37
Legal regulations.................................................................................38
Stationary protection...........................................................................38
Mobile protection................................................................................39
Standards...................................................................................... 41
The floor
High rack storage areas where man-down narrow aisle trucks are
used are technically advanced systems today. The use of highlevel order pickers, racking trucks and order picking trucks in such
warehouses not only requires technically highly developed industrial
trucks, but also floors of above average quality. They must be capable of carrying loads, level, and horizontal, and meet the strictest
tolerances for travel paths of the VDMA directive (the tolerances
according to DIN 18202 apply for all remaining surfaces).
Only compliance with the VDMA directive requirements can guarantee the full performance of the trucks and their associated productivity. Testing the floor surface for evenness should be done directly
after installing the floor, and before beginning any subsequent work.
Proof of compliance with the tolerances is provided by the floor
installer or a neutral surveyor office
(also see: www.VDMA.org/Branchen/Logistiksysteme).
Sub-concrete
Iron reinforcement
Make sure that the overall traffic surface never exceeds the
allowed tolerances and meets the required level of technology
(honing the floor finish over levelled guide rails typically does
not guarantee the necessary floor tolerances for trucks).
Discontinuities in the flooring, such as channels or shafts, require
a minimum spacing of 200 mm to the travel paths and should be
avoided in the aisle whenever possible.
Evenness tolerances
Zslope
dz = Z x Zslope
bis 6
2.0
Z x 2.0 mm/m
10
1.5
Z x 1.5 mm/m
15
1.0
Z x 1.0 mm/m
Zslope
Permissible slope crosswise to the path between the middle of the
load wheels of the industrial truck (a, b) in mm/m (the value of
Zslope is specified dependent on the lift height)
Specifications for evenness for the very narrow aisle range are defined for three different areas:
a.) height differences crosswise to the travel path
b.) height differences longitudinally along the travel path
c.) rippled variations in height differences
Z
Dimension between the centres of the load wheels of industrial trucks
(a, b) in m
These three factors have a decisive influence on the driving performance and non-compliance can lead to a reduction in handling
performance.
dZ
Maximum permissible height differences between the centres of
load wheels of industrial trucks (a, b)
dz
Height difference = dz
Track width = Z
Load wheels = a, b
Zslope (mm/m)
2
1.75
1.5
0.5
8
10
15
T lift height (m)
dZ (mm)
1.75
4
1.5
1.25
3
2.625
1.0
2
1
0
0.5
1.5
2.5
Z (m)
Delta X
Delta X
Point X
Hx
+ dz
Zero line
Track width
Ast
dz
Ast
Hx = height of point X
above the floor
b1 = safety distance
10
Example:
The inside micrometer below a 2 m long straight edge must not be
greater than 3 mm (see Fig. 6).
1m
2 mm
2m
3 mm
3m
4 mm
4m
5 mm
l=2m
t = 3 mm
11
/-FX
Fx or O
15
>_ 525
10
>_ 400
up to 6
>_ 300
12
Example calculation:
Assumption: lift height = 8 m; travel path Z = 1.5 m
Calculation of Z slope using Fig. 2: 1.75 mm/m
Calculation of dz using Fig. 3: Z x Z slope = 2.625 mm
Calculation of Fx using Fig. 6: Fx >_ 350
10
15
Lift height (m)
13
The racking
14
Pallet racks consist of vertical racks and horizontal bridge pieces (DIN
EN 15620). Support beams, grating, steel panels, or particleboard can
be placed on these, depending on application profile. If the distance
between the inside of the stored loads for double racks is less than
100 mm, a push-through guard is mounted for protection.
Free-standing pallet racks are not permanently joined to the building.
They can be set up flexibly, and can be used later for other applications by switching them around.
DIN EN 15512 Stationary racking systems made of steel adjustable
pallet racks basis for static measurement forms the basis for static
verification when building such racks.
Requirements for fire protection are an another important factor
when building racking storage. We recommend early contact with
15
Side view
CX
CZ
Y-direction
GY
GY
JX
H1
H
JZ
HB
Detail
E1
H1A
M
X-direction
Z-direction
D
Top view
A1(n)
A
GZ
B0
B1
B2
B3
Bn
HY
F
Z-direction
F1
X-direction
16
Table 4: Installation tolerances and permissible deformations of the racks according to DIN EN 15620
Horizontal tolerances for the XZ plane (mm)
Measurement specification and description of the cross deviation
Deviation from the nominal size of the access width between two support uprights
in any beam height
+- 3
A1
Deviation from the nominal value for the total length of the racking, cumulative number n for
the fields, measured as close as possible to the base plate
+- 3 n
Misalignment of the supports in transverse direction, speed, cumulative for the Number
n the fields measured approximately at ground level. For this class 300A applies only
to the support uprights. Class 300B applies to the support uprights and the rear pillars.
B0
Deviation from the nominal size of the racking front at the transfer aisle
the respective reference line of the racking system Z measured near ground level
+- 10
CX
+- H/500
CZ
Single frame: +- 3
Double frame: +- 6
Deviation from the nominal size for the aisle width about ground level
+- 5
E1
Deviation from the nominal size for the width between the rails
+5
0
E2
+- 5
Deviation from the nominal size of the aisle straightness measured approximately
at ground level with respect to the reference line aisle system X or according
to the specifications of the truck supplier
+- 10
F1
Deviation measured between next to each other uprights around Ground level in the Z direction
+- 5
GZ
+- A/400
JX
+- 3 or +- HB/750*
JZ
+- H/500
TW
1 per m
GY
+- 3 or +- A/500*
H1
Deviation of the top level of any beam over the H1 lower support level
300A: +- 5 or +- H1/500
300B: +- 3 or +- H1/1000*
H1A
Deviation of the top edge of the lower beam on each upright against ground level
+- 7
H3
HY
Deviation of the heights of the load unit between the front and rear beam
in one compartment
+- 10
Height from the top of the foot stand level to top of the racking support
HB
Height from the top stand level to the next higher stand level
a H/500 is also permitted, provided the overhang of the pallet skids or blocks at the front bars is 75 mm
or more and the skids or blocks are supported by the beams.
17
X1
18
19
Ast
Aisle width, clear width between the loads or between the racks
The mechanical guide has rollers attached to the truck and steel
profiles mounted to the floor to guide the industrial truck. The laterally mounted rollers hold the truck between the profiles in the aisle
centre.
F = Ast/2
Permissible deviation of the aisle width from the centre line to 20 m
- F = +- 5 mm
Fig.10 shows the minimum width of the aisle (Ast) taking into consideration the relevant parameters.
b26
Clear width between the rails
b6
Truck width over guide rollers b6 = b26 5 mm
Permissible deviation:
- over the entire length: -0/+5 mm
- over 1 meter length: -0/+2 mm
F
Ast
Distance between the guide rails -b26Truck width over the guide rollers -b6-
Sub-concrete
2.5 mm
20
Iron reinforcement
2.5 mm
a21/a23
min.
50 mm
21
22
Ast
500 mm
500 mm
300 mm
300 mm
300 mm
300 mm
300 mm
15
23
Rack
Frequency generator
Return of an inductive
guide wire
Distance between t wo
guide wires with the same
frequency: min. 1200 mm
24
140 mm
Receiver antennas
Transmitting antennas
(coil)
Guide wire
10 mm
50 mm
6 mm
Iron reinforcement
Sub-concrete
25
automated operation. The smaller the tracking angle, the faster the
truck lines up (displayed by an optical and acoustic message). The
guide wire should be pulled in as far as possible in the changeover
aisle. The minimum dimension here is a truck length plus 500 mm
(see Fig. 17).
Exit from the aisle
After exiting out of the aisle, the driver switches back to manual
mode and the truck can be driven again freely.
Maximum tracking
angle 60
26
Optimum tracking
angle 45
Frequency generator
The frequency generator has connections for a max. of 8 separate
loops with each up to 2000 m summing up to a total of 16000 m. It
feeds the guide wire with high frequency AC. If a single driving loop
is damaged this loop then fails entirely. Therefore it is recommended
to reduce downtimes by splitting of the wire guidance in a warehouse in different loops.
27
28
End of the
aisle safety
features
Lift and .
raction.
cut-outs
VNA.
navigation
Magnets
Reflected light
sensors
Bar codes
RFID
29
Magnets
Linde magnets are very small (31 mm diameter, 25 mm height)
and thus very simple and cost-effective to install. Two magnets are
installed in the floor at approx. 6 cm distance, one behind the other.
Depending on if the south pole or the north pole magnet is driven
over first, the truck detects in which direction the truck is moving
and thus, if and how the truck must brake. To be able to represent
different functions, there is also the option to place the magnets 150
mm or 300 mm off centre. Magnets are ideal in storage areas where
simple traction and lift reductions are necessary.
1000
N
30
Vmax
V-Check/
Beginning of aisle end zone
Temporary stop
Vred
300
Temporary stop
Middle
of aisle
Vred
150
Drive direction
Vmax
Fig. 21: End of aisle safety features using reflected light sensors
Open end of aisle
B
Specify
on site
1000
D
A
Vmax
Vred
V check/temporary stop
Vred
Middle
of aisle
Lrack
Drive direction
Vmax
31
Bar codes
Linde bar codes are attached approx. 50 cm above the floor on
all rails. The truck scans the bar code and can determine its exact
position in the storage area. Exactly determining a location makes it
possible to assign various reactions from the truck to a location. In
this way, the most varied and complicated truck functions such as
lift and driving restrictions can be implemented. Exactly determining
a location is also the basis for Lindes very narrow aisle navigation
system as it supports the driver during storage and removal of the
correct pallets and avoids errors.
32
RFID
Linde RFID tags are especially small and can be installed very quickly
and easily in the floor with a standard drilling machine. They work
at a frequency which enables fast reading and writing on the tags.
Even if the tags get wet, they are protected and retain their function.
The truck reads the RFID tags and can exactly determine its position
in the storage area. Exactly determining a location makes it possible
to assign various reactions for the truck to a location. In this way, the
most varied and complicated truck functions such as lifting and driving restrictions can be implemented. Exactly determining a location
is also the basis for Lindes very narrow aisle navigation system as it
supports the driver during storage and removal of the correct pallets
and avoids errors.
33
Height-dependent cut-offs
When system-dependent components, such as joists, pipes, and
cable racks restrict the effective range and height of the industrial
trucks, lift-height dependent cut-offs must be provided.
Bridgeable intermediate lift limitation
In this interlock, the lifting movement is always switched off using
a switch before reaching the critical overhead clearance. The driver,
once he is convinced that the industrial truck is not in the danger
area, can continue the lifting movement by pressing an acknowledge
button and actuating the lift valve. When the highest height of the
industrial truck has exceeded the critical height, driving is only possible at creep speed.
34
VNA navigation
Using Lindes very narrow aisle navigation system can increase handling performance and at the same time, ensure secure storing and
removing of stock by preventing errors. Additionally, the navigation
system makes the work easier for the driver and also makes it possible for new drivers to quickly work efficiently.
The truck receives its transport or picking order via data transmission
from the warehouse management system on its truck terminal. Using
the navigation system, the truck can move in the fastest possible
way from its current position to the required pallet storage location. The driver only has to steer using the drive and lift lever. This
ensures that the driver has both hands within the truck contours
and thus cannot be injured. The truck moves in an ideal curve to the
specified pallet storage location. Storing or removing the pallet in the
wrong location is ruled out.
35
36
37
Legal regulations
In accordance with the workplace regulation 1.8. , pathsways, point
(3) a side clearance for pedestrians on each side of the industrial
truck in a VNA aisle should be guaranteed . Although a defnite value
is not given the clearance taken as a guideline is 50cm on each side
which is derived from the DIN EN 349.
In BetrSichV, basic options to protect persons in very narrow aisle
warehouses are described as technical or structural measures. Structural measures typically do not suffice, thus only a technical solution
is offered. There is a distinction here between stationary (photosensor equipment on the very narrow aisle entrances) or mobile
(systems installed on the truck) systems.
If you operate a very narrow aisle warehouse or want to start operation in a new very narrow aisle warehouse the protective measures
should be on an up to date standard. In germany they should meet
the performance level b.
Stationary protection
Each access of the very narrow aisle is individually protected with a
photosensor system. Emergency exits and access doors are normally
protected by swinging doors.
Photosensors for
truck detection
Controller
Controller
Photosensors for
personnel detection
38
Mobile protection
The industrial truck is equipped with laser sensors on both sides.
These monitor the travel path and detect when a person is in the
warning field or the alarm field. If a person is detected in the warning field, the speed is automatically reduced to creep speed (max.
2.5 km/h). If a person is detected in the alarm field, a alarm is
triggered and the truck is braked automatically until standstill. For
reasons of safety, the alarm can only be reset by the driver after the
truck is completely at a standstill. The monitoring equipment is not
active outside the very narrow aisles.
Assembly of the scanner
For reasons of space, the scanner can only be attached in most cases
to the front side behind the fork. This means that if the fork is lowered, there is no view and thus also no safety function. In this case,
the industrial truck may only drive at creep speed (max. 2.5 km/h).
A magnet operated switch on the lift mast will determine if the
scanner has an unencumbered view. The scanner is then activated.
If there are no other speed limitations (cross aisles or the end of the
very narrow aisle), the industrial truck can move at maximum speed
in the very narrow aisle.
39
Additional function
In order to have fully functioning mobile personal protection measures, e.g. detection of drive direction, end of aisle, cross aisles, or
exiting aisle, additional elements are required.
Drive direction sensor
A drive direction sensor is attached on one of the two non-driven
trailing wheels. This detects the direction of movement as well as the
speed and performs a distance measurement.
Additional functions
To increase safety, additional functions are implemented using the
drive direction sensor. At commissioning, the braking distance of the
industrial truck is measured from full speed to standstill. Braking distance and delay are then saved in the controller. During each braking
process the actual braking distance is measured and compared with
the stored braking distance. The driver is notified of diminishing
braking efficiency via the terminal. Afterwards, the truck can only be
operated at creep speed for safety reasons.
Position detection
Position detection can be performed using reflected light sensors
with coded reflection marks on the rack or using aisle magnets with
magnet operated switches. The first coding is located on the access
to the very narrow aisle. When this coding is detected, the protection
system is initialised, i.e. the drive direction sensor starts the distance
measurement and determines the drive direction. The protective
fields are activated.
Laser scanner
Alarm field
Warning field
40
Standards
Cited standards
D
IN EN 1045 Part 2: Concrete, reinforced and prestressed concrete
structures - Part 2: Concrete - Specification, properties, production
and conformity
D
IN EN 1045 Part 3: Concrete, reinforced and prestressed concrete
structures - Part 3: Execution of structures
Additional standards
D
IN 15184: Power operated industrial trucks; industrial trucks for
rack operation, technical safety requirements and testing
F EM 9.831 Calculation principles of storage and retrieval machines.
Tolerances. Deformations and clearances in the high-bay warehouse
FEM 10.3.01 Pallet racks, tolerances, deformations, and clearances
D
IN EN 1081: Resilient floor coverings - Determination of the
electrical resistance
D
IN EN 15620: Steel static storage systems - Adjustable pallet
racking - Tolerances, deformations and clearances
V
DMA directive Floors for use with very narrow aisle industrial
trucks
D
IN EN 15635: Steel static storage systems - Application and
maintenance of storage equipment
D
IN EN 15512: Steel static storage systems - Adjustable pallet
racking systems - Principles for structural design
D
IN EN 15629: Steel static storage systems - Specification of
storage equipment
D
IN EN 1726 Part 2: Safety of industrial trucks - Self-propelled
trucks up to and including 10000 kg capacity and tractors with
a drawbar pull up to and including 20000 N - Part 2: Additional
requirements for trucks with elevating operator position and trucks
specifically designed to travel with elevated loads
Linde Material Handling ranks among the worlds leading manufacturers. This position has been justly earned. Linde trucks
excel not only with their recognized innovative technology but especially their low energy and operating costs, which can be
as much as 40% less than competitors.
High quality in production is matched by the standard of the services we provide. With a comprehensive network of local
sales partners, we are at your call around the clock and around the world.
Your local Linde partner offers you a complete single-source package. From qualified pre-sales consulting through the sale
to after-sales service; including finance packages matched to your business requirements. Leasing, rental or hire purchase.
Flexibility is maintained in your operational and decision-making processes.