2010.07.08 - Presentation - English - Infotag Lagertechnik 2010 - FEM 9 841+10 2 10 - Kopya

FEM 9.841 / FEM 10.2.
10
Product Groups : Intra Logistic Systems + Racking & Shelving
Storage Systems Operated by Storage & Retrieval Machines Interfaces

However not: - Deformations, Tolerances and Clearances - Safety Back Stops (EN 528: 2008) FEM 9.831-1 FEM 9.832 FEM 9.842 FEM 10.2.11
ir. C.J. Tilburgs Technical Chairman ERF / FEM Racking & Shelving Chairman FEM WG 9.831 / 9.841 / 9.842
European Racking Federation ERF / FEM Racking & Shelving
FEM 9.841 / FEM 10.2.10
VDMA Infotag Lagertechnik 10 Juni 2010
CONTENT
A. B. Why the FEM 9.841 / FEM 10.2.10 Scope FEM 9.841 / FEM 10.2.10
C.
D.
Obligations Storage System Designer

Items part of FEM 9.841 / FEM 10.2.10, e.g. : 1. Concrete slab of the Warehouse 2. Actions Imposed on the Steel Structure with Loads Cycling 3. Vibrations 4. Seismic Area 5. Fire Safety EN 528: 2008 & Pallet Safety Back Stops
E.
FEM 9.841 / FEM 10.2.10
A. WHAY THE FEM 9.841 / FEM 9.10.10

1. THE FEM 9.223
Gives only attention points and who (e.g. Client, General Contractor, Planner, Architect) is responsible for what, however NO concrete relevant Interface Issues
Therefore the FEM 9.841 / FEM 10.2.10

FEM 9.841 / FEM 10.2.10
VDMA Infotag Lagertechnik 10 Juni 2010 3
WHY THE FEM 9.841 / 10.2.10 (2)
2. When drafting FEM 9.831-1 by the WG

also other relevant issues were tabled and discussed. than Tolerances Deformations Clearances
3. Storage Systems become more and more Complex

Timely Considerations AND Decisions do become more and more important :
Assumptions Facts !!!

(In principle BEFORE the design of the warehouse building!!)
FEM 9.841 / FEM 10.2.10
WHY THE FEM 9.841 / 10.2.10 (3)
4. The Steel Structure (Racking) becomes more and more the Construction Work of a Storage Machine a. Dynamic Quasi-static (via Dynamic Factor) b. Specification of the Spectrum with Load Cycles
Examples:
FEM 9.841 / FEM 10.2.10
EXAMPLES STORAGE MACHINE
Crane Aisle
Crane Aisle
Crane Aisle
Crane Aisle
EN 528 : Safety Operators Machine

FEM 9.841 / FEM 10.2.10
WHY THE FEM 9.841 / 10.2.10 (4)
5. Building Sites
more and more with lesser load bearing properties Not always complying with the requirement Quasi-stiff concrete slab in accordance with FEM 9.831-1 / 9.832 Interactive design : Concrete Slab Racking
FEM 9.841 / FEM 10.2.10
WHY THE FEM 9.841 / 10.2.10 (5)
6. Daily Pracice (onfortunately)

Project Specification with ALL relevant Data for the entire Storage System (e.g. Racking + S/R Machines + - - - - )
Suppliers with Professional Knowledge do have an Advanced Position, however with Constraints: They know too much + Cause Problems !!! (the competition has simply accepted) Storage System Designer, is he aware of all his responsibilities ???
FEM 9.841 / FEM 10.2.10
B. SCOPE FEM 9.841 / FEM 10.2.10

1. Guideline with Backgrounds to the specification of Interfaces between Sub - Systems
(of rail dependent S/R Storage - Systems) ,

relevant for Functionality, Performance and Safe Use 2. Concrete Cases which might occur, with relevant starting points, obligations, responsibilities and data to be specified by parties involved
FEM 9.841 / FEM 10.2.10
WHY THE FEM 9.841 / 10.2.10 (2)
3. Storage & Retrieval Machine in the general sense Stacker crane (S/R Machine) - on a concrete slab , rail dependent - supported by racking , rail dependent Shuttle - pallet storage - small parts storage Traverse car And such
FEM 9.841 / FEM 10.2.10
10
C. DUTIES OF THE
STORAGE SYSTEM DESIGNER
1. Definition
(Storage) System Designer = Planer (FEM 9.223)
Person or functionality responsible for:

- Overall (total) design of the storage system
- Functionality, performance and safe use of the storage system
For instance : Logistic Consultant /

General Contractor / Client himself
(shall be clear for each project)
FEM 9.841 / FEM 10.2.10
11
DUTIES OF THE SYSTEM DESIGNER (2)
Is the one who calls himself System Designer really the Storage System Designer ???
This person or functionality has to create the end-conditions to allow the signing of a CE Declaration of Conformity
See next slides

European Racking Federation ERF / FEM Racking & Shelving VDMA Infotag Lagertechnik 10 Juni 2010
FEM 9.841 / FEM 10.2.10
12
2. Quantification of the Logistic Needs of the Client
Unit loads Load Make-up Accessories Quantities Variations etc.
Storage-System
2 3 i
Different Unit loads Load Make-up Accessories Quantities Variations etc.
Warehouse Building
FEM 9.841 / FEM 10.2.10
13
3. Consulting the Client about Alternatives

Pro and Cons alternatives 1, 2 i Investment for alternatives 1, 2 i Return on Investment
4. Description of the Storage System Chosen

with end conditions / quantified performances with regard to Sub Systems (e.g. Concrete slab, Unit Loads, S/R Machines, Travel rails, Racking, Guide rails) Interfaces between Sub - Systems
FEM 9.841 / FEM 10.2.10
14
5. Request for Quotation

Project Specification with all relevant data
Guidelines FEM 9.233 FEM 9.831-1 & FEM 9.842 AND FEM 9.841
6. Evaluation of Quotations
a. Reliability b. Compliance (Appel with Appel) c. Delivery times
d. Price setting
e. ......
FEM 9.841 / FEM 10.2.10
15
7. Final clearity
a. Possible Unclearness b. Possible Assumptions
Clearness Facts
Offering Stage
8. Contracting
Alle relevant data are specified clear & quantified Ordering to Sub Suppliers
9. Project - Management
10. Hand - over
FEM 9.841 / FEM 10.2.10
16
11. Information Flow Chart

Realisation Logistic Centre In general 3 Parties are involved :
END USER / CLIENT
WAREHOUSE BUILDING DESIGNER
STORAGE SYSTEM DESIGNER
FEM 9.841 / FEM 10.2.10
17
Examples of relevant issues for the System Designer

FEM 9.223 STORAGE SYSTEM DESIGNER FEM 9.841
FEM 9.841 / FEM 10.2.10
18
Examples of relevant issues for the Warehouse Building Designer
FEM 9.841 / FEM 10.2.10
19
D. ITEMS IN FEM 9.841 - EXAMPLES

D1. WAREHOUSE FLOOR SLAB
a. Type of foundation , e.g. : Ground bearing
Suspended (e.g. piling)
FEM 9.841 / FEM 10.2.10
20
WAREHOUSE SLAB (2)
b. Non uniform Loading?
Storage with A-B-C Principle

with different statistical weight variation
(1) In use from hand-over on (2) Empty in the beginning
FEM 9.841 / FEM 10.2.10
21
WAREHOUSE SLAB (3)
c. Period of Loading
Concrete has better properties under Short Term Loading
Examples of Short Term Loading :

Wind Load (e.g. Rack clad building)
Effects of 2nd Order Rack Deformations
LONG TERM LOADING (1) Direct effect weights Unit Loads (1st Order) SHORT TERM LOADING (2) Slender upright frames
(1) (2)
Column buckling (2nd Order)
FEM 9.841 / FEM 10.2.10
22
WAREHOUSE SLAB (4)
d. Concrete slab NOT Quasi Stiff Iterative design procedure with interactive behaviour :
Rack Design Slab Design
The Storage System Designer has to cordinate !!!
Carries the Slab the Racking or the reversed situation ??
FEM 9.841 / FEM 10.2.10
23
WAREHOUSE SLAB (5)
e. Anchoring Compression or Tension Zones ? - Designer of concrete slab shall specify - Slab supported by piles Always Tension Zones
Tension Zone above
Compression Zone above
- Pulling out strength Same anchor type : in Tension Zone << in Compression Zone
FEM 9.841 / FEM 10.2.10
24
WAREHOUSE SLAB (6)
f. Attention in case of Steel Fibre Concrete
- Only anchors which are certified according the European Construction Directive are allowed : * CE * ETAG
- No certified anchor type exists for steel fibre concrete
(ETAG only specifies normal mortar ; Steel fibre additive results in a special mortar)
- Always to be checked in advance with the checking Professional Engineer or Building Official
FEM 9.841 / FEM 10.2.10
25
ITEMS IN FEM 9.841 / FEM 10.2.10 (2)
D2. IMPOSED LOADS ON THE RACKING WITH LOAD CYCLES

a. Examples
1. 2. 3. 4. 5. Upper guide rail, S/R Machine moving Upper guide rail, S/R Machines deposits or picks Rail Pallet- / Small Parts Shuttle Rail for Traverse Car Connections and supporting structure of the rails mentioned in (1) (4). 6. S/R machine supported by the racking.
FEM 9.841 / FEM 10.2.10
26
IMPOSED LOADS WITH LOAD CYCLES (2)
b. The Storage Systems have changed

For instance: 1. Higher drive- (X-) and deposit (Z-) speeds 2. 24 Hours Economy 3. The upper guide wheels are clamped on the guide rail
(because of high velocities: contact between wheel tyre and rail running suface is required at all times)
Lateral Guide Force higher always present
FEM 9.841 / FEM 10.2.10
27
c. Consequences
1. A fatigue check might be reguired in certain situations Partial Safety Factor for Fatique (EN 1993-1-9) a. Damage Tolerant situation, e.g. :.
- in case cracks unexpectedly do occur , a low rate of propagation and long critical crack length - provision of readily inspectable detail for regular inspections
(Reference Locations for Inspections)
b. Safe approach : fatigue life will be reached with the required safety level
Choice Mf in relation with specification load spectrum
(conservative or realistic spectrum)
1,35
EN 1993-1-9
FEM 9.841 / FEM 10.2.10
28
2. Concrete quantified design parameter are required
Load spectrum with number of load cycles over the design life
(in accordance with the designed operation)
or simplified & on the safe side : Constant (*) Load Amplitude with Number of Load Cycles to match
(*) Attention : is NOT the average value
FEM 9.841
FEM 9.841 / FEM 10.2.10
29
Safety factor for fatique to consider : Mf = 1,0 / 1,15 / 1,35 ? Aplication points of the forces
FEM 9.841 / FEM 10.2.10
30
d. Retro Fit
One shall consider also:
Higher drive and / or depositing / picking velocities

More S/R Machine movements per day
FEM 9.841 / FEM 10.2.10
31
e. Example: Rail for a Pallet - Shuttle

1. Wheel loads
(1) Contact Area For instance: 80 mm a = 20 mm bxc = 15x5 mm F1 F2

= F4 = 0 = F3 = dyn X (Total Weight) / (4 or ?? )

FEM 9.841 / FEM 10.2.10
LOAD CYCLES AND PALLET - SHUTTLE RAIL (2)
2. Peak Stresses under the Wheel
Finite Shell Element Analysis - Wheel at mid span - Wheel at rail end
(1) Rail Bending (2) Rail Torsion
+
Flange Bending
ca. Factor 2 in Stress Level

European Racking Federation ERF / FEM Racking & Shelving VDMA Infotag Lagertechnik 10 Juni 2010
FEM 9.841 / FEM 10.2.10
33
LOAD CYCLES AND PALLET SHUTTLE - RAIL (3)
3. Driving into a Rack Lane
(1) Wheel position at the instant of leaving the S/R Machine (2) > appr. 80 mm (3) At all time > appr. 2 mm
FEM 9.841 / FEM 10.2.10
34
LOAD CYCLES AND PALLET SHUTTLE RAIL (4)
4. Leaving a Rack Lane
(1) Wheel position when just supported by S/R Machine (2) > appr. 80 mm (3) At all time > appr. 2 mm
Assumption (to be confimed by a FEM analysis): due to increasing rail flange deformation under F1 when approaching the rail end , F1 will decrease while F2 will increase
FEM 9.841 / FEM 10.2.10
35
ITEMS FEM 9.841 / 10.2.10 (3)
D3. VIBRATIONS (EN 528, clause 5.10.7.3)

When the following conditions are met Especially relevant in case of Mini-Load Systems with Small Weights of the Unit Loads and / or Anti-Pendel S/R Machine
Tolerances and Deformations of Drive Rail and Upper Guide Rail are in accordance with FEM 9.831-1 or FEM 9.832 Tolerances and Deformations of the S/R Machine are complying with the requirements Regular Maintenance Wear and tear of the drive and guide wheels remain withing specified limits
Effect of possible Vibrations Negligible

(No unintended load movement ; No bolt securing issue)
FEM 9.841 / FEM 10.2.10
ITEMS FEM 9.841 /FEM 10.2.10 (4)
D4. SEISMIC AREA

a. Design
General for Construction Work : EN 1998-1 Design of structures for earthquake resistance
Part 1 : General rules, seismic actions and rules for buildings
Additional for Pallet Racking : FEM 10.2.08:2010

Recommendations for the design of static steel pallet racking under seismic conditions
Attention concerning calculated Seismic Forces :

FEM 10.2.08 (1,25 1,3) x RMI-USA
European Racking Federation ERF / FEM Racking & Shelving VDMA Infotag Lagertechnik 10 Juni 2010 37
FEM 9.841 / FEM 10.2.10
SEISMIC AREA (2)
b. Data to be specified for the Seismic Design of the Rack Structure , e.g.
1. Rack filling grade reduction factor (down aisle) 2. Soil characteristics 3. Character of stored goods
(compact, flexible, liguids)
4. Reduced design weight Unit Loads, at an Earthquake ?? 5. Type of LMA (e.g. wood, dry or wet ; plastic ; steel) 6. Seismic design life, Normal : 50 Jahre, Reduced : 30 Jahre 7. Interfaces with Warehouse Building, e.g. :
- Additional Upright- and Anchoring forces - Seismic Sway deformation Warehouse Building
FEM 9.841 / FEM 10.2.10
38
SEISMIC AREA (3)
8. Importance Class
Fully automated, - No Persons , or with e.g. - Pick Aisles Hazardous stored goods Hig Bay Warehouse directly bordering area, as e.g.: Transit Area, Picking Area and / or Gang / Traffic Ways
H(2) > 2 H(1) ???

as Pick aisles
(1) Transit / Picking Warehouse (2) Fully automated High Bay Warehouse
European Racking Federation ERF / FEM Racking & Shelving VDMA Infotag Lagertechnik 10 Juni 2010 39
FEM 9.841 / FEM 10.2.10
SEISMIC AREA (4)
c. Load case Earthquake has to be taken seriously
Video
FEM 9.841 / FEM 10.2.10
40
ITEMS FEM 9.841 /FEM 10.2.10 (5)
D5. FIRE SAFETY

a. National Rules & Legislation b. Requierements from Local Fire Officials are determinative c. Unprotected steel has a negligible Fire Resistance (appr. 5-8 Minuten) FIRE RESISTANCE (S-Class F20, F30, F60, F90)
Time in Minutes the load carrying capacity is still given with the imposed loads required, nd with the Temperature Action imposed as well (Standardised Fire-Curve : EN 1991-1-2) , until collapse will take place.
Partial Safety Factor : = 1.0

FEM 9.841 / FEM 10.2.10
FIRE SAFETY (2)
Standardised Fire Curve
TSteel > 400 C Strength
After Minutes 5 10 20
TEnvironment (C) 475 700 750
d. Active Fire Safety Measures are necessary, as e.g. :

Short Escape Routes Smoke Alarm Sprinkler
NOTE: Persons are workers in the internal logistics (e.g. order pickers) No Disabled
FEM 9.841 / FEM 10.2.10
42
FIRE SAFETY (3)
e. Requirement : Racking imposed by a Fire shall Implode in case of a collapse ??!!

To prove : Special Finite Element Soft Ware Package However , is without the additional effect of falling Unit-Loads , which might result in an additional Collapse of certain Rack Components
FEM 9.841 / FEM 10.2.10
43
E. EN 528: 2008 & SAFETY BACK STOPS

a. Clause 5.6.3 : Limitation of forces
The racking supplier shall be advised of the kinetic energy and additional forces to be able to calculate the resulting forces.
However the S/R Machine absorbs a relative big part of the Kinetic Energy
AKTIVE ROLE : Supplier of the S/R Machine

FEM 9.841 / FEM 10.2.10

EN 528 : 2008 & SAFETY BACK STOPS (2)
b. EKin
Quasi Static Collision Force
A relative complex phenomenon Research fml / TU Mnchen

3D + Crash Simulation
Complex calculation model
Simplified model for daily practice FEM 9.842 / FEM 10.2.11

FEM 9.841 / FEM 10.2.10
SAFETY BACK STOP
EKin COLLISION FORCE
In principle there are 3 Compoments who have to absorb EKin :

Racking S/R Machine Load make-up accessory (e.g. Pallet) + Load on it e.g. 15 - 30 % of EKin
e.g. 3D < 7.5 2D

FEM 9.841 / FEM 10.2.10
46

2010.07.08 - Presentation - English - Infotag Lagertechnik 2010 - FEM 9 841+10 2 10 - Kopya

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FEM 9.841 / FEM 10.2.

Storage Systems Operated by Storage & Retrieval Machines Interfaces

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

Obligations Storage System Designer

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

A. WHAY THE FEM 9.841 / FEM 9.10.10

European Racking Federation ERF / FEM Racking & Shelving

Therefore the FEM 9.841 / FEM 10.2.10

WHY THE FEM 9.841 / 10.2.10 (2)

2. When drafting FEM 9.831-1 by the WG

3. Storage Systems become more and more Complex

Assumptions Facts !!!

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

WHY THE FEM 9.841 / 10.2.10 (3)

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

EXAMPLES STORAGE MACHINE

EN 528 : Safety Operators Machine

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

WHY THE FEM 9.841 / 10.2.10 (4)

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

WHY THE FEM 9.841 / 10.2.10 (5)

6. Daily Pracice (onfortunately)

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

B. SCOPE FEM 9.841 / FEM 10.2.10

(of rail dependent S/R Storage - Systems) ,

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

WHY THE FEM 9.841 / 10.2.10 (2)

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

Person or functionality responsible for:

For instance : Logistic Consultant /

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

DUTIES OF THE SYSTEM DESIGNER (2)

See next slides

FEM 9.841 / FEM 10.2.10

DUTIES OF THE SYSTEM DESIGNER (3)

2. Quantification of the Logistic Needs of the Client

Unit loads Load Make-up Accessories Quantities Variations etc.

Different Unit loads Load Make-up Accessories Quantities Variations etc.

European Racking Federation ERF / FEM Racking & Shelving

FEM 9.841 / FEM 10.2.10

VDMA Infotag Lagertechnik 10 Juni 2010

DUTIES OF THE SYSTEM DESIGNER (4)

3. Consulting the Client about Alternatives

4. Description of the Storage System Chosen

FEM 9.841 / FEM 10.2.10