2010.07.08_presentation_english_infotag lagertechnik 2010_fem 9 841+10 2 10 - kopya

VDMA Infotag Lagertechnik

10 Juni 2010

European Racking FederationERF / FEM Racking & Shelving FEM 9.841 / FEM 10.2.10

FEM 9.841 / FEM 10.2.10Product Groups : “Intra Logistic Systems” + “Racking & Shelving”

Storage Systems Operated by“Storage & Retrieval Machines – Interfaces”

1

However not:

- Deformations, Tolerances and Clearances FEM 9.831-1FEM 9.832

- Safety Back Stops (EN 528: 2008) FEM 9.842FEM 10.2.11

ir. C.J. Tilburgs

Technical Chairman ERF / FEM “Racking & Shelving”

Chairman FEM WG 9.831 / 9.841 / 9.842


10 Juni 2010

European Racking FederationERF / FEM Racking & Shelving

CONTENT

A. Why the FEM 9.841 / FEM 10.2.10

B. Scope FEM 9.841 / FEM 10.2.10

C. Obligations Storage System Designer

D. 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

E. EN 528: 2008 & Pallet Safety Back Stops

FEM 9.841 / FEM 10.2.10 2


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A. WHAY THE FEM 9.841 / FEM 9.10.10

FEM 9.841 / FEM 10.2.10 3

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

FEM 9.841 / FEM 10.2.10 Therefore the


10 Juni 2010


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 :

FEM 9.841 / FEM 10.2.10 4

WHY THE FEM 9.841 / 10.2.10 (2)

Assumptions Facts !!!

(In principle BEFORE the design of the warehouse building!!)


10 Juni 2010


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

FEM 9.841 / FEM 10.2.10 5

Examples:


10 Juni 2010

European Racking FederationERF / FEM Racking & Shelving FEM 9.841 / FEM 10.2.10

EXAMPLES STORAGE „MACHINE“

CraneAisle

CraneAisle

CraneAisle

CraneAisle

EN 528 : “Safety”

Operators Machine


10 Juni 2010

European Racking FederationERF / FEM Racking & Shelving FEM 9.841 / FEM 10.2.10 7

5. Building Sites

more and more with lesser

load bearing properties

Not always complying with the requirement “Quasi-stiff“ concrete slabin accordance with FEM 9.831-1 / 9.832

Interactive design : Concrete Slab Racking

WHY THE FEM 9.841 / 10.2.10 (4)


10 Juni 2010


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 8


10 Juni 2010


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 9


10 Juni 2010


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


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C. DUTIES OF THE

STORAGE SYSTEM DESIGNER

1. Definition

FEM 9.841 / FEM 10.2.10 11

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

(Storage) System Designer = Planer (FEM 9.223)

(shall be clear for each project)


10 Juni 2010


DUTIES OF THE SYSTEM DESIGNER (2)

FEM 9.841 / FEM 10.2.10 12

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


10 Juni 2010



2. Quantification of the Logistic Needs of the Client

FEM 9.841 / FEM 10.2.10 13

Unit loads

Load Make-up

Accessories

Quantities

Variations

etc.

Different

Unit loads

Load Make-up

Accessories

Quantities

Variations

etc.

Storage-System

Warehouse Building

1

3

2

i


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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


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5. Request for Quotation

Project Specification with all relevant data

FEM 9.841 / FEM 10.2.10 15

6. Evaluation of Quotations

a. Reliability

b. Compliance (“Appel with Appel”)

c. Delivery times

d. Price setting

e. ......

Guidelines FEM 9.233 FEM 9.831-1 & FEM 9.842

AND FEM 9.841


10 Juni 2010



7. Final clearity

a. Possible Unclearness Clearness Offering

b. Possible Assumptions Facts 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


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11. Information „Flow Chart“

Realisation Logistic Centre

FEM 9.841 / FEM 10.2.10 17

END USER / CLIENT

WAREHOUSE BUILDING

DESIGNER

STORAGE SYSTEM

DESIGNER

In general 3 Parties are involved :


10 Juni 2010



FEM 9.841 / FEM 10.2.10 18

STORAGE SYSTEM DESIGNER FEM 9.841

Examples of

relevant issues for the System – Designer

FEM 9.223


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Examples of

relevant issues for the Warehouse Building Designer

FEM 9.841 / FEM 10.2.10 19


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D. ITEMS IN FEM 9.841 - EXAMPLES

D1. WAREHOUSE FLOOR SLAB

FEM 9.841 / FEM 10.2.10 20

a. Type of foundation , e.g. :

Ground bearing

Suspended(e.g. piling)


10 Juni 2010


WAREHOUSE SLAB (2)

b. Non – uniform Loading?

FEM 9.841 / FEM 10.2.10 21

Storage with A-B-C Principle

with different statistical

weight variation

(1) In use from hand-over on

(2) Empty in the beginning


10 Juni 2010


WAREHOUSE SLAB (3)

c. Period of Loading

FEM 9.841 / FEM 10.2.10 22

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

Concrete has better properties under „Short Term“ Loading

(1)

(2)

“Column – buckling (2nd Order)


10 Juni 2010


WAREHOUSE SLAB (4)

d. Concrete slab NOT “Quasi – Stiff“

FEM 9.841 / FEM 10.2.10 23

Iterative design procedure with interactive behaviour :

Rack Design Slab Design

The Storage System Designer has to coördinate !!!

Carries the Slab

the Racking or

the reversed situation ??


10 Juni 2010


WAREHOUSE SLAB (5)

e. Anchoring

FEM 9.841 / FEM 10.2.10 24

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


10 Juni 2010


WAREHOUSE SLAB (6)

FEM 9.841 / FEM 10.2.10 25

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


10 Juni 2010


ITEMS IN FEM 9.841 / FEM 10.2.10 (2)

D2. IMPOSED LOADS ON THE RACKING

WITH LOAD CYCLES

FEM 9.841 / FEM 10.2.10 26

a. Examples

1. Upper guide rail, S/R Machine moving

2. Upper guide rail, S/R Machines deposits or picks

3. Rail Pallet- / Small Parts Shuttle

4. Rail for Traverse Car

5. Connections and supporting structure of the rails mentioned in (1) – (4).

6. S/R machine supported by the racking.


10 Juni 2010


IMPOSED LOADS WITH LOAD CYCLES (2)

b. The Storage Systems have changed

FEM 9.841 / FEM 10.2.10 27

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


10 Juni 2010



c. Consequences

FEM 9.841 / FEM 10.2.10 28

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

1,35

EN 1993-1-9

Choice Mf in relationwith specificationload spectrum

(conservative or realistic spectrum)


10 Juni 2010



2. Concrete quantified design parameter are required

FEM 9.841 / FEM 10.2.10 29

FEM 9.841

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 Amplitudewith Number of Load Cycles to match

(*) Attention : is NOT the average value


10 Juni 2010



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


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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


10 Juni 2010



e. Example: Rail for a Pallet - Shuttle

FEM 9.841 / FEM 10.2.10 32

1. Wheel loads

For instance: ！ ≈ 80 mma = 20 mmbxc = 15x5 mm

F1 = F4 = 0

F2 = F3 = βdyn X (Total Weight) / (4 or ?? )

(1) Contact Area


10 Juni 2010


LOAD CYCLES AND PALLET - SHUTTLE RAIL (2)

2. Peak Stresses under the Wheel

FEM 9.841 / FEM 10.2.10 33

Finite „Shell“ Element Analysis

- Wheel at mid span

- Wheel at rail end

ca. Factor 2 in Stress Level

(1) Rail Bending

(2) Rail Torsion

+

Flange Bending


10 Juni 2010


LOAD CYCLES AND PALLET SHUTTLE - RAIL (3)

3. Driving into a Rack Lane

FEM 9.841 / FEM 10.2.10 34

(1) Wheel position at the instant of „leaving“ the S/R Machine

(2) > appr. 80 mm

(3) At all time > appr. 2 mm


10 Juni 2010


LOAD CYCLES AND PALLET SHUTTLE RAIL (4)

4. Leaving a Rack Lane

FEM 9.841 / FEM 10.2.10 35

(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


10 Juni 2010


ITEMS FEM 9.841 / 10.2.10 (3)

D3. VIBRATIONS (EN 528, clause 5.10.7.3)

FEM 9.841 / FEM 10.2.10 36

When the following conditions are met

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 thedrive and guide wheels remain withing specified limits

Effect of possible Vibrations Negligible

Especially relevant in case of Mini-Load Systems with Small Weights of the Unit Loads

and / or Anti-Pendel S/R Machine

(No unintended load movement ; No bolt securing issue)


10 Juni 2010


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“

FEM 9.841 / FEM 10.2.10 37

● 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 á 1,3) x RMI-USA

ITEMS FEM 9.841 /FEM 10.2.10 (4)


10 Juni 2010


SEISMIC AREA (2)

b. Data to be specified for the

„Seismic Design of the Rack Structure“ , e.g.

FEM 9.841 / FEM 10.2.10 38

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


10 Juni 2010


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

(1) Transit / Picking Warehouse

(2) Fully automated High Bay Warehouse

FEM 9.841 / FEM 10.2.10 39

H(2) > 2 H(1) ???

as „Pick aisles“


10 Juni 2010


SEISMIC AREA (4)

c. Load case „Earthquake “

has to be taken seriously

FEM 9.841 / FEM 10.2.10 40

Video


10 Juni 2010


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)

FEM 9.841 / FEM 10.2.10 41

FIRE RESISTANCE (S-Class F20, F30, F60, F90)

Time in Minutes the load carrying capacity is still given

with the imposed loads required,

ánd with the Temperature Action imposed as well

(Standardised Fire-Curve : EN 1991-1-2) ,

until collapse will take place.

ITEMS FEM 9.841 /FEM 10.2.10 (5)

Partial Safety Factor : = 1.0


10 Juni 2010


FIRE SAFETY (2)

Standardised Fire Curve

FEM 9.841 / FEM 10.2.10 42

After Minutes TEnvironment (C°)

5 ≈ 475

10 ≈ 700

20 ≈ 750

d. „Active“ Fire Safety Measures are necessary, as e.g. :

Short Escape Routes

Smoke Alarm

Sprinkler

TSteel > 400° C Strength

NOTE: Persons are workers in the internal logistics (e.g. order pickers)

No Disabled


10 Juni 2010


FIRE SAFETY (3)

e. Requirement : Racking imposed by a Fire

shall „Implode“

in case of a collapse ??!!

FEM 9.841 / FEM 10.2.10 43

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


10 Juni 2010


E. EN 528: 2008 & SAFETY BACK STOPS

a. Clause 5.6.3 : Limitation of forces

FEM 9.841 / FEM 10.2.10 44

„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


10 Juni 2010


EN 528 : 2008 & SAFETY BACK STOPS (2)

b. EKin Quasi – Static Collision Force

FEM 9.841 / FEM 10.2.10 45

A relative complex phenomenon

Research „fml“ / TU München

3D + Crash Simulation

Complex calculation model

FEM 9.842 / FEM 10.2.11

Simplified model for daily practice


10 Juni 2010


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

FEM 9.841 / FEM 10.2.10 46

e.g. „3D“ < 7.5 „2D“

2010.07.08_presentation_english_infotag lagertechnik 2010_fem 9 841+10 2 10 - kopya

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