The hit list of IFOY nominees: Robotized, cube-shaped warehouse systems are in high season. e.scala is a highly standardized goods-to-person system that uses a single robot to replace all the traditional components of an automated warehouse and can be installed in just three months.

The e.scala is a robot-based storage and picking system. The robot moves in three dimensions within a storage cube and easily reaches any point in a warehouse or production area via a rail system. A patented ramp system allows the robots to move from storage level to storage level and overcome height differences outside the storage cube. The high level of flexibility allows virtually any customer requirement to be met using standard modules.

During the IFOY test days in Dortmund, the ramp assembly was lifted into the test hall in one piece. The only moving part is the rail-mounted shuttle, which stow calls "Robot"—it couldn't be simpler. Otherwise, the customer gets pure redundancy. The strength of e.scala lies in its relatively straightforward entry into automation.

One of its unique selling points is that the entire system consists of only 15 different parts. However, only the "exciting" warehouse pre-zone with three lines for accessing four levels in the warehouse was demonstrated at the test camp. How the system works is also reflected in the product name: The "e" comes from escalator. The term "scala" is intended to demonstrate scalability. The entire installation requires no vertical lift, i.e., no elevator. The individual aisles are accessed via inclined ramps, which significantly reduces the risk of errors. The "connector" is the section where the robot can change direction in order to move the goods to be transported into or out of the warehouse and, with or without transported goods, to change levels.

Photo: IFOY / Schütze

In principle, as the auditors in the IFOY audit also determined, the system is similar to a parking garage, although the actual order system is usually located outside the warehouse. The manufacturer also places great importance on the system's redundancy: According to the manufacturer, the only thing that could break is the robot. However, it doesn't then block the entire system.

The transport robot has eight wheels: four for travel in the X direction, while the other four move the robot in the Y direction after the wheel change. The entire structure essentially only requires two power sources: once for the charging station, where the individual robots can charge their power packs—with a charging time of eight seconds, they can travel for about twelve minutes—and once for Wi-Fi robot communication with the warehouse management system. This also means that no cables are installed in the entire pre-zone.

The individual modules of the e.scala system are designed to measure 5.0 meters x 2.5 meters and are scalable. The system can easily accommodate a total height of 24 meters. Stow Traffic Control (STC) detects when the robot passes over the installed passive RFID tags in the respective section of the route.

Because the system is highly standardized, it can easily meet even small requirements, starting with 500 storage locations to be automated. Because the system's 15 basic components and the robot can be delivered directly from stock, an entire system can be planned and implemented within a very short time. Even in the event of a robot failure, the system's availability is exceptionally high, as access to every location in the system is guaranteed at all times via multiple paths.

Because low initial investments and easy scalability later on are crucial for automating smaller systems, e.scala seems to be ideal for SMEs that don't want to go all out with their investment in automated intralogistics right away.

The actual IFOY award winners will remain secret until the very end. The IFOY gala and awards ceremony will take place on June 30 at BMW Welt in Munich.

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