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6.7 High-Bay Warehouse (HBW)

Overview

The HBW (High-Bay Warehouse) is a storage system that stores and retrieves workpieces. It has multiple storage positions organized in a grid and uses an automated retrieval system.

Module Type: HBW
Serial Number: Cleaned variant of the SPS serial number
Storage Capacity: Typically 9 positions (3x3 grid)

Supported Commands

Command Purpose Metadata Duration
PICK Store workpiece from AGV into warehouse StoreMetadata (type, workpieceId) ~10-15 seconds
DROP Retrieve workpiece from warehouse to AGV None ~10-15 seconds

⚠️ Note: Like DPS, HBW has inverted command logic:

  • PICK = Store (take from AGV, put in warehouse)
  • DROP = Retrieve (take from warehouse, put on AGV)

Supported Instant Actions

Action Purpose Metadata Description
factsheetRequest Request module info None Triggers publication of factsheet message
reset Reset module None Return module to initial state
SET_STORAGE Update storage contents contents map Manually set inventory state (e.g. after intervention)
startCalibration Enter calibration mode None Switch operating mode to TEACHIN
stopCalibration Exit calibration mode None Switch operating mode to AUTOMATIC
setCalibrationValues Update calibration Calibration data Update internal position values

MQTT Topics

Standard module topics:

  • Subscribe: module/v1/ff/<serial>/order, module/v1/ff/<serial>/instantAction
  • Publish: module/v1/ff/<serial>/state, module/v1/ff/<serial>/connection, module/v1/ff/<serial>/factsheet

Command Examples

Example 1: PICK (Store Workpiece)

Command:

{
  "timestamp": "2024-12-08T10:00:00.000Z",
  "serialNumber": "HBW001",
  "orderId": "order-store-123",
  "orderUpdateId": 1,
  "action": {
    "id": "pick-action-abc",
    "command": "PICK",
    "metadata": {
      "type": "BLUE",
      "workpieceId": "wp-67890"
    }
  }
}

Behavior:

  1. System identifies free storage position
  2. Picks workpiece from AGV
  3. Transports workpiece to storage position
  4. Stores workpiece in identified slot
  5. Updates internal storage map

State Response (Finished):

{
  "headerId": 25,
  "timestamp": "2024-12-08T10:00:12.000Z",
  "serialNumber": "HBW001",
  "type": "HBW",
  "orderId": "order-store-123",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "pick-action-abc",
    "timestamp": "2024-12-08T10:00:12.000Z",
    "state": "FINISHED",
    "command": "PICK"
  },
  "errors": [],
  "loads": [
    {
      "loadType": "BLUE",
      "loadPosition": "2-1",
      "loadId": "wp-67890"
    }
  ]
}

The loadPosition indicates storage location (e.g., "2-1" = column 2, row 1).

Example 2: DROP (Retrieve Workpiece)

Command:

{
  "timestamp": "2024-12-08T10:30:00.000Z",
  "serialNumber": "HBW001",
  "orderId": "order-retrieve-456",
  "orderUpdateId": 1,
  "action": {
    "id": "drop-action-def",
    "command": "DROP"
  }
}

⚠️ Note: The CCU determines which workpiece to retrieve based on order requirements and FIFO/LIFO logic.

Behavior:

  1. System locates requested workpiece type
  2. Retrieves workpiece from storage position
  3. Transports to AGV interface
  4. Places on AGV loading bay
  5. Updates internal storage map

State Response (Finished):

{
  "headerId": 30,
  "timestamp": "2024-12-08T10:30:14.000Z",
  "serialNumber": "HBW001",
  "type": "HBW",
  "orderId": "order-retrieve-456",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "drop-action-def",
    "timestamp": "2024-12-08T10:30:14.000Z",
    "state": "FINISHED",
    "command": "DROP"
  },
  "errors": [],
  "loads": []
}

Storage Management

Storage Position Naming

Storage positions follow the format: <column>-<row>

Example 3x3 grid:

1-3  2-3  3-3  (Top row)
1-2  2-2  3-2  (Middle row)
1-1  2-1  3-1  (Bottom row)

Set Storage Instant Action

To manually configure storage contents (e.g., after manual intervention or system reset):

Instant Action:

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T09:00:00.000Z",
  "actions": [
    {
      "actionType": "SET_STORAGE",
      "actionId": "set-storage-123",
      "metadata": {
        "contents": {
          "1-1": {
            "type": "WHITE",
            "workpieceId": "wp-111"
          },
          "2-1": {
            "type": "BLUE",
            "workpieceId": "wp-222"
          },
          "3-1": {
            "type": "RED",
            "workpieceId": "wp-333"
          }
        }
      }
    }
  ]
}

Empty positions can be omitted or explicitly set to {}.

Hardware Details

Physical Components

The HBW consists of:

  • X-Axis: Horizontal movement (columns)
  • Y-Axis: Vertical movement (rows)
  • RBG (Regalbediengerät): Storage/retrieval unit with gripper
  • Encoders: Position tracking for X and Y axes
  • Light Barriers: Workpiece detection

PLC I/O

Inputs:

  • Y-axis reference switch
  • X-axis encoder (A/B)
  • Y-axis encoder (A/B)
  • Gripper front light barrier
  • Gripper rear light barrier

Outputs:

  • X-axis motor (to storage rack)
  • X-axis motor (to conveyor)
  • Y-axis motor (down)
  • Y-axis motor (up)
  • Gripper motor (extend)
  • Gripper motor (retract)
  • PWM signals (X-axis, Y-axis, Gripper)

Calibration

The HBW requires precise calibration of:

  • X-axis Positions: Exact encoder values for each column
  • Y-axis Positions: Exact encoder values for each row
  • Gripper Positions: Extend/retract distances
  • Timing Parameters: Movement speeds

See Calibration Documentation for procedures.

Errors

  • PICK_ERROR - Failed to store workpiece (storage full, position error, gripper fault)
  • DROP_ERROR - Failed to retrieve workpiece (no workpiece in requested position, gripper fault)
  • Storage full errors are reported via error messages

Storage State Tracking

The CCU tracks HBW storage state via:

  • Topic: ccu/state/stock
  • Contents: All workpieces in storage with positions

Example:

{
  "ts": "2024-12-08T10:00:00.000Z",
  "stockItems": [
    {
      "workpiece": {
        "id": "wp-111",
        "type": "WHITE",
        "state": "RAW"
      },
      "location": "HBW",
      "hbw": "1-1"
    },
    {
      "workpiece": {
        "id": "wp-222",
        "type": "BLUE",
        "state": "RAW"
      },
      "location": "HBW",
      "hbw": "2-1"
    }
  ]
}

Special Considerations

Inverted Command Logic

  • PICK = Store into warehouse (take from AGV)
  • DROP = Retrieve from warehouse (give to AGV)

Storage Strategy

  • CCU implements FIFO (First In, First Out) by default
  • Alternative strategies can be configured

Empty Storage Handling

  • System must handle "no workpiece available" scenarios
  • Orders may be delayed waiting for retrieval

Related Documentation

OPC UA Variables

Variable Name Description Type
model Model name STRING
stat__busy Status: System in use BOOL
stat__pickActive Status: Pick process active BOOL
stat__pickFinished Status: Pick process finished BOOL
cmd__pick Command: Pick operation BOOL
cmd__pickTargetRack Target rack for pick operation STRING
stat__dropActive Status: Drop process active BOOL
stat__dropFinished Status: Drop process finished BOOL
cmd__dropTargetRack Target rack for drop operation STRING
cmd__drop Command: Drop operation BOOL
stat__calibActive Status: Calibration active BOOL
cmd__calibrate Command: Calibrate BOOL
cmd__movePosX Target position in X direction for move, only during calibration DINT
cmd__movePosY Target position in Y direction for move, only during calibration DINT
cmd__movePosRot Target position in rotational direction for move, only during calibration DINT
cmd__default Command: Reset to default values BOOL
stat__defaultFinished Status: Reset to default values finished BOOL
cmd__move Command: Move operation BOOL
stat__moveFinished Status: Move operation finished BOOL
cmd__endCal Command: End calibration BOOL
stat__endCalFinished Status: Calibration ended BOOL
rack__A1_workpieceId Workpiece ID at position A1 in rack (Same for A2-C3) STRING
rack__A1_occupied Status: Position A1 in rack occupied (Same for A2-C3) BOOL
rack__A1_type Type of position A1 in rack (Same for A2-C3) STRING
cal__row1 Calibration value for row 1 DINT
cal__row2 Calibration value for row 2 DINT
cal__row3 Calibration value for row 3 DINT
cal__rackOffset Calibration value for rack offset DINT
cal__colA Calibration value for column A DINT
cal__colB Calibration value for column B DINT
cal__colC Calibration value for column C DINT
cal__rampPositionX Calibration value for ramp position in X DINT
cal__rampPositionY Calibration value for ramp position in Y DINT
cal__rampPositionRot Calibration value for ramp position in rotational direction DINT
cal__rampPositionRotCheck Calibration value for rotational check position of ramp in rotational direction DINT
cal__rampOffset Calibration value for ramp offset DINT
cal__AGVPositionRot Calibration value of FTS rotation DINT
cal__upperLimitX Calibration upper limit for X DINT
cal__lowerLimitX Calibration lower limit for X DINT
cal__upperLimitY Calibration upper limit for Y DINT
cal__lowerLimitY Calibration lower limit for Y DINT
cal__upperLimitRot Calibration upper limit for rotational direction DINT
cal__lowerLimitRot Calibration lower limit for rotational direction DINT
cal__timeProcessEnd Calibration time at process end TIME
stat__referencedRotationalAxis Status: Rotational axis referenced BOOL
stat__referencedXAxis Status: X-axis referenced BOOL
stat__referencedYAxis Status: Y-axis referenced BOOL
cal__timeGripperValveOpen Time for opening the gripper valve TIME
cal__timeGripperValveClose Time for closing the gripper valve TIME
cal__timeCompressor Time for the compressor TIME
cmd__park Command: Park operation BOOL
cal__parkPositionX Park position in X direction for calibration DINT
cal__parkPositionY Park position in Y direction for calibration DINT
cal__parkPositionRot Park position for rotation in calibration DINT
stat__parkActive Status: Park operation active BOOL
rack__A1_ts Timestamp for position A1 in rack (Same for A2-C3) STRING
cal__defRowA Default value for row A DINT
cal__defRowB Default value for row B DINT
cal__defRowC Default value for row C DINT
cal__defOffset Default value for offset DINT
cal__defParkPositionX Default park position in X direction DINT
cal__defParkPositionY Default park position in Y direction DINT
cal__defParkPositionRot Default park position for rotation DINT
cal__defCol1 Default value for column 1 DINT
cal__defCol2 Default value for column 2 DINT
cal__defCol3 Default value for column 3 DINT
cal__defRampPositionX Default value for ramp position in X DINT
cal__defRampPositionY Default value for ramp position in Y DINT
cal__defRampPositionRot Default value for ramp position in rotational direction DINT
cal__defRampPositionRotCheck Default value for rotational check position of ramp in rotational direction DINT
cal__defRampOffset Default value for ramp offset DINT
cal__defAGVPositionRot Default value of FTS rotation DINT
cal__defUpperLimitX Default upper limit for X DINT
cal__defLowerLimitX Default lower limit for X DINT
cal__defUpperLimitY Default upper limit for Y DINT
cal__defLowerLimitY Default lower limit for Y DINT
cal__defUpperLimitRot Default upper limit for rotational direction DINT
cal__defLowerLimitRot Default lower limit for rotational direction DINT
cal__defTimeProcessEnd Default time at process end TIME
cal__defTimeGripperValveOpen Default time for opening the gripper valve TIME
cal__defTimeGripperValveClose Default time for closing the gripper valve TIME
cal__defTimeCompressor Default time for the compressor TIME