Custom size Line-side Racks for Lean Manufacturing?

Custom AGV Flow Rack with Blue KLT Bins for Line-side Supply

The “One-Size-Fits-All” Myth in Automotive Logistics.

If you are managing an assembly line, you know that standard pallet racking is useless at the line-side. You are dealing with specific dunnage dimensions, tight takt times, and the absolute necessity of removing forklifts from the aisles. You need a carrier that fits your specific KLT boxes, withstands the torque of Underride AGV lifting, and guarantees FIFO without manual intervention.

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The Conflict: Static Shelving vs. Dynamic Mobility

In the transition to a “Forklift-Free” factory floor, the biggest bottleneck isn’t the robot—it’s the rack. Traditional manufacturing racks are designed to sit still. They rely on gravity to keep beams locked into uprights (the hook-and-slot method). But when you introduce a Porta Mobile per SPS (Set Parts Supply) strategies, the physics change entirely.

When an Underride AGV tunnels beneath a rack and activates its hydraulic lift, it applies an upward force that counters gravity. In a standard rack, this can unseat the beams, causing catastrophic structural failure during transport. Furthermore, the vibrations from constant movement across expansion joints can loosen welded joints over time.

Underride AGV lifting a Fully Bolted Structure rack

Figure 1: A SpaceDAS rack featuring a Fully Bolted Structure to withstand dynamic AGV lifting forces.

Our Solution: The Fully Bolted “Rigid Frame”

At SpaceDAS, we don’t build shelves; we build mobile chassis. We utilize a Fully Bolted Structure with anti-loosening lock nuts. This creates a rigid frame that maintains its geometry whether it is sitting on the floor or being accelerated at 1m/s² by a robot. This is critical for maintaining the precise tolerances required for robotic docking.

Gravity Flow and FIFO: The Heart of Line-side Efficiency

Custom sizing isn’t just about fitting the footprint; it’s about optimizing the flow. In high-volume automotive assembly, operators cannot waste seconds searching for parts. The rack must present the next part automatically.

We design custom Gravity Flow layers angled specifically for your dunnage (plastic KLTs, blister trays, or cardboard). By calculating the friction coefficient of your specific bins, we determine the exact slope (typically 3-5%) to ensure reliable feeding without crushing the operator’s fingers.

Custom Gravity Flow Rack design for FIFO management

Figure 2: Engineered roller tracks ensure strict First-In-First-Out (FIFO) compliance for line-side assembly.

This design allows for “Decoupling”:

This separation is vital for safety and maintaining the production beat (Takt).

Request a Custom Drawing for Your Dunnage

Heavy Loads: Handling EV Batteries and Powertrains

The rise of New Energy Vehicles (NEVs) has introduced heavier components to the line-side. A standard aluminum pipe-and-joint rack (common in older lean setups) often lacks the tensile strength to hold a 200kg EV Battery Module or heavy stamping dies without deforming.

We utilize High-tensile Steel Q355 for our structural uprights. Unlike modular pipe systems that require constant re-tightening (maintenance), our steel structures are “install and forget.” This allows you to deploy heavy-duty Alimentazione in linea that can be safely transported by heavy-duty AGVs, bridging the gap between the warehouse and the final assembly line.

Heavy duty custom rack for automotive shafts and parts

Figure 3: Custom heavy-duty racking designed for specific automotive shafts, moved by AGV.

Karakuri: The Next Step in Automation

Why stop at moving the rack? Custom sizing allows us to integrate Karakuri (automazione a basso costo) mechanisms directly into the rack structure. We can design “Shooter” mechanisms where the AGV docks at the workstation, and a mechanical lever releases the bins, shooting them onto the conveyor automatically using gravity.

Blue custom flow rack with AGV docked for automatic unloading

Figure 4: A custom “Shooter” rack demonstrating mechanical integration with an AGV for hands-free material transfer.

Frequently Asked Questions (FAQ)

1. Can you design racks to fit our specific KLT / VDA boxes?
Absolutely. We design the rack aperture (width and height) based exactly on your dunnage (KLT 6410, 4314, etc.) to maximize density. We verify the “flow” angle to ensure boxes slide smoothly without gaining dangerous speed.
2. Do your racks work with any AGV brand?
Yes, we are equipment agnostic. We customize the bottom clearance and leg width to accommodate Hikrobot, Geek+, MiR, or any other Underride AGV. We just need the robot’s dimension sheet.
3. How do you prevent parts from falling during AGV cornering?
For high-speed transport, we integrate active locking bars or passive tilt angles. For heavy items like Telai automobilistici parts, we can add mechanical interlocks that only open when the AGV reaches the designated station.
4. Can these racks handle ESD sensitive components like ECUs?
Yes. For electronic sub-assemblies, we use ESD powder coating or nickel-plated rollers and install conductive chains/castors to ensure a resistance to ground of 10^5 to 10^9 ohms, protecting sensitive electronics.
5. What is the advantage of a bolted structure over a welded one for maintenance?
If a forklift or AGV accidentally damages a leg, a welded rack often needs to be scrapped or requires hot work (welding) on the plant floor, which is a safety hazard. With our fully bolted structure, you can simply unbolt and replace the damaged component, reducing downtime.