7.7.2025 / 5-minute read

Furniture Plant Triple VRC System | Automated Panel Handling

Overview

System Concept: A high-throughput vertical handling solution for furniture manufacturing, featuring three synchronized Slat Chain VRCs.

Enables automated cross-floor transport of panels/pallets with roller conveyor integration, eliminating manual handling damage and elevator delays.

Pain Points

  • Variable panel sizes (1200x2400mm to 2200x4000mm) caused manual handling damage
  • 3-floor workflow: 1F→2F(cutting)→3F(edging) with elevator bottlenecks
  • Peak demand: 200+ pallets/day, labor costs >25% of operational expenses

Solution Architecture

ComponentSpecifications
VRC Units3 slat-chain VRCs @ 2.5m center distance
Per Unit Capacity2000kg / 3.2×1.8m platform / 0.3m/s speed
Conveyor InterfaceInfeed: Heavy-duty roller with photoelectric positioning
Outfeed: Bi-directional for floor switching
Panel ProtectionSilicone-coated platform + nylon edge guards
Control SystemCentralized PLC with multi-unit coordination algorithm

Quantified Benefits

  • 🚀 Efficiency Gains:
    • Cycle time: 90s → 50s/pallet (-44%)
    • System throughput: 150 pallets/hour
  • 💸 Cost Reduction:
    • Eliminated 6 forklift operators, saving $50,000+/year
    • Material damage rate: 3% → 0.5%
  • 🔧 Strategic Advantages:
    • Real-time OEE monitoring via central HMI
    • ±3mm platform leveling accuracy for smooth transfer

Working Principle

  1. Intelligent Infeed:
    • Pallets move via heavy-duty rollers at 1F, scanned & weighed
    • Photoelectric sensors detect panel size, PLC assigns optimal VRC
  2. Vertical Transport:
    • Platform ascent: VFD-driven dual-chain system @ 0.3m/s (soft start/stop)
    • Precision positioning: Encoder + magnetic scale ensure ±3mm leveling
  3. Floor Transfer:
    • 2F outfeed rollers route pallets based on MES:
      • Edging required → bi-directional conveyor to 3F VRC
      • Direct storage → 2F buffer zone
    • Empty descent: 30% energy consumption vs. loaded ascent

Customization Options

DimensionFurniture-Specific CustomizationStandard Options
Platform– Replaceable silicone pads
– Pneumatic side clamps		Size: 1.5×1m ~ 6×3m
Load CapacityLightweight design (≤2000kg) for MDF/particleboard500kg~10,000kg
InterfaceRoller conveyor options:
– Gravity rollers
– Powered accumulation		AGV/Chain/RGV integration
Environment– Sawdust guards (chain protection)
– Anti-static coating		ATEX/IP65/Cryogenic
Smart Control– MES connectivity
– AI vision for panel sizing		PLC selection (Siemens/AB)

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