The Challenge
Coordinating Heavy Pallets Across Multiple AGV Lines Without Manual Sorting
The customer needed an automated buffer and queuing system to manage palletized motor assemblies moving between upstream production and downstream AGVs. The system specifications included:
- Handling pallets weighing up to 800 lbs
- Integrating between two separate AGV systems and mezzanine operations
- Supporting storage on raised platforms
- Eliminating need for manual pallet shuffling or forklift dependency
MWES was selected to engineer a dynamic pallet buffering system that enabled safe, high-throughput flow without manual sorting or rehandling.
The Solution
Gantry-Based AS/RS with RFID Tracking, Storage Racks & AGV Integration
MWES delivered an AS/RS buffer system featuring:
- A 2-axis pick-and-place gantry servicing two storage racks on either side of the gantry, each with 48 pallet slots (96 total)
- Integrated RFID readers on the gantry to validate and track each pallet during storage and retrieval
- Multidirectional pallet lifts/elevators at both ends of the mezzanine for vertical transport
- Conveyor-based load and unload stations and two operator stations (pallet load side and unload side) for efficient flow
MWES delivered a highly coordinated pallet buffering system that automates pallet sorting, storage, and delivery between AGV systems—without requiring forklift intervention.
The Results
Dynamic Pallet Access, Reduced Energy Use & Future Expansion Capability
The implemented AS/RS system provided the following measurable benefits:
- Any pallet can be retrieved directly, without recirculation or reorganization
- Maintains pallet orientation automatically throughout storage and retrieval
- Minimizes mechanical motion and energy draw compared to full shuttle systems
- Scalable capacity—additional rack zones can be added if mezzanine space allows
With this buffer system, MWES enabled flexible pallet handling, reduced labor complexity, and improved material flow between production and automation systems—all in a modular and upgradeable layout.
