SpaceDAS System Installation Process

Phase 1: Geotechnical Validation & Rail Precision

For Plant Managers in the automotive or heavy equipment sector, the nightmare scenario is “settlement.” If your slab shifts, a stacker crane operating at 30 meters high will experience amplified oscillation, leading to sensor errors and downtime.

The SpaceDAS installation begins long before the steel arrives. We conduct a rigorous survey of your facility’s floor load capacity. Unlike standard warehousing where minor unevenness is acceptable, our AS/RS System demands a floor flatness classification of “Super Flat.”

The Critical Path:

• Chemical Anchoring: We do not rely on standard expansion bolts. We utilize deep-set chemical anchors to secure the Bottom Rail. This ensures that the dynamic forces of a crane accelerating at 2m/s² with a heavy load do not shear the fasteners over time.
• Laser Leveling: The ground rail is leveled using industrial laser interferometry to ensure a deviation of less than 1mm over 100 meters. This is the physical foundation for the system’s ±3mm positioning accuracy.

Phase 2: Structural Erection & The “Rack Clad” Advantage

Once the foundation is cured, we begin the vertical assembly. For clients utilizing our Rack Clad design, this phase effectively constructs your building and your storage simultaneously. We use Q355 High-Strength Steel, connected entirely via bolts (no site welding). This Fully Bolted Structure provides superior resistance to the dynamic fatigue caused by thousands of daily storage cycles.

In this phase, we install the Top Guide Rail. This is not merely a capstone; it connects the rack structure rigidly to the building roof or the rack-clad ceiling, eliminating the “whiplash effect” at the top of the mast during high-speed braking.

Phase 3: Electrification & The “Handshake”

With the skeleton in place, we install the nervous system. This involves running the busbar systems for power and the optical data transmission lines along the aisle. In modern heavy industry setups, we integrate Regenerative Braking Units into the power supply, allowing the Stacker Crane to feed energy back into the grid during the descent of heavy pallets.

The Logic Integration (WMS/PLC)

This is where hardware meets intelligence. We connect the SpaceDAS PLC (Programmable Logic Controller) to your existing WMS (Warehouse Management System) or ERP (like SAP). The goal is to establish a seamless “handshake” protocol.

The Safety Sandbox: Before we go live, we configure the “Profile Gauge” (the external dimension scanner). If a pallet of engine blocks has an overhang greater than 50mm due to shifting during transport, the system is programmed to reject entry immediately. This prevents a potential jam or collision 20 meters in the air, protecting your expensive dies and the machinery itself.

Phase 4: Site Acceptance Testing (SAT) & Handover

We do not hand over the keys until the system passes the Stress Test. This involves running the system at 110% of the designed throughput for a continuous period, simulating peak production shifts.

We verify:

• Positioning Accuracy: Verifying the laser positioning system hits the target coordinate within ±3mm every time.
• Emergency Protocols: Triggering E-Stops and verifying that the clamps engage instantly to prevent load dropping.
• Throughput Validation: proving the system can handle the required pallets/hour to feed your assembly line without starving the bottleneck.

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Frequently Asked Questions (Heavy Industry Focus)

Question	Answer
Can we install SpaceDAS while our production line is still running?	Yes. We use a phased installation approach. We can erect the structure in partitioned zones with safety barriers, ensuring your forklifts can continue to feed the line from existing buffer stocks during construction.
How deep does the concrete foundation need to be for heavy die storage?	Para Heavy Duty ASRS storing loads of 3,000kg to 8,000kg, standard warehouse slabs are insufficient. We typically require deep pile anchoring or a reinforced mat foundation, which our engineering team will calculate based on your soil report.
Does the system integrate with our AGV fleet?	Absolutely. We design specific “AGV Handshake Stations” at the head of the aisles. The SpaceDAS conveyor interface is height-matched to your automated forklifts or AGVs to allow for autonomous induction and retrieval without human intervention.
What happens if a hydraulic hose bursts on a heavy load stacker?	SpaceDAS cranes for heavy loads utilize electric servo drives for lifting, not hydraulics, to eliminate fluid leaks and contamination. For the few hydraulic components (if used in specific clamping mechanisms), we install catch pans and rupture valves to lock the load in place instantly.
How do you handle “Black Box” anxiety regarding the software?	We don’t build black boxes. We provide open API documentation for your IT team and transparent HMI (Human Machine Interface) panels that show exactly what the crane is doing, which sensor is active, and the logic state of every command in real-time.