11.17.2025 / 5-minute read
Fork-Type Cyclic Lifting System for Distribution Center Automation
Project Overview
Client: E-commerce Distribution Center
Industry: Logistics & Warehousing
Application: Multi-Level Package Sorting System
Core Challenge: To achieve efficient vertical transportation and automatic sorting of various packaged goods between multiple warehouse levels while maintaining high throughput and reliability.
Basic Parameters
| Parameter | Specification |
|---|---|
| Load Capacity | 500 kg per cycle |
| Lifting Speed | 0.5 m/s |
| Positioning Accuracy | ±1 mm |
| Operation Levels | 5 floors |
| Control System | PLC with Ethernet/IP |
| Package Types | Cartons, totes, boxes, crates |
| Interface | Bidirectional conveyor integration |
The Challenges
- Vertical Transportation Bottlenecks: Existing elevators couldn’t handle continuous package flow between five operational levels
- Sorting Complexity: Manual sorting processes caused delays and errors in order fulfillment
- Package Diversity: Needed to handle various packaging types including cartons, plastic totes, and boxes
- Space Optimization: Required minimal footprint while maximizing vertical transportation capacity
Solution
- Flexible Configuration: Multiple inlet/outlet configurations adapt to existing facility layouts
- Precision Positioning: ±1mm accuracy enables seamless transfer to conveyor systems
- High Reliability: 99.5% operational availability in continuous 24/7 operation
- Gentle Handling: Smooth acceleration and deceleration protect fragile goods
- Seamless Integration: Standard interfaces connect with existing sortation systems
- Increased Throughput: 400% improvement in vertical transportation capacity
- Reduced Labor Costs: Eliminated 8 manual material handling positions
- Improved Accuracy: 99.9% sortation accuracy across multiple levels
- Enhanced Safety: Complete elimination of manual lifting injuries
Details
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