Fully-Scalable Robotic Warehouse System

Feb. 14, 2019
Bastian Solutions' latest AutoStore release offers a slimmer robot and taller bin heights.

The AutoStore Black Line and Red Line systems are innovative storage solutions that allow complete configurability and flexibility. Bins are stacked vertically in a grid and retrieved by robots that travel on the top layer of the system. This makes it possible for the grid to be placed around columns, on mezzanines, and on multiple levels.


AutoStore Red Line is the fastest-growing robotic warehouse system and has pioneered cube-based automation to revolutionize warehousing with a simple, reliable and flexible solution. To take AutoStore’s game-changing functionality to the next level, the company has now developed a new robot and workstation to service the highest demand systems.


An AutoStore system is comprised of 4 main components: a structural grid, delivery robots, storage bins, and an operator port. Products are stored in stacked bins within the dense aluminum grid. As a product is needed to fulfill an order, the system software and controls alert a robot to find the bin containing the item.


If the bin is buried beneath other bins, a robot stages the extra bins on top of the grid until it retrieves the desired bin. It then takes that bin to the edge of the grid and delivers it to the operator fulfilling the order. As the bin is delivered, another AutoStore robot cleans up the staged bins on top of the grid by returning them to their original position.


As this process continues, the AutoStore system self-profiles, meaning the bins with faster moving products begin moving toward the top of the system, and bins with slower moving products transition to the bottom.

Black Line Features:
  • Higher throughput, more efficient 24/7 operations, and taller bins for high-demand systems
  • Most new components are compatible with old components
  • New double-double grid means robots can pass in all directions in tighter, more sophisticated patterns     
  • B1 robot:
    • Size: covers 1.5 storage cells
    • 75% higher acceleration than R5, due to brushless direct-drive motors in each wheel
    • 30 bins per hour per B1 robot. accommodating 220, 330, and 425 bin heights
    • Lithium ion battery pack swap in 20 seconds, 99% run time
    • Smaller footprint/higher robot density
  • Relay port is fastest workstation ever
    • 650 bins per hour with B1 robots, minimum bin exchange time of 2 seconds


Red Line Features:

  • Most cost-effective choice for low and medium throughput operations
  • Uses single-double grid, meaning robots can only pass each other in one direction
  • R5 robot
    • Size: covers 2 storage cells
    • Accommodates 220 mm and 330 mm bins
    • 3.1 m/s drive speed
    • 71 dB sound
    • Cycle charging requires additional R5 robots to compensate
  • Carousel port
    • 250 bins per hour with R5 robots
    • 300 bins per hour with B1 robots