Environmentally Friendly Products

Energy conservation in the mini load AS/RS

Daifuku's mini load AS/RS is appropriate for the storage and retrieval of items in containers and cardboard boxes and is widely used in distribution centers and factories of various industries. Daifuku upgraded the mini load AS/RS in 2010, reducing the size of the stacker cranes by 10% and the weight by 15% (from 1,850 kg to 1,580 kg). Moreover, with a decrease in motor size and the efficient use of regenerated power, the AS/RS helps reduce customers' operating costs (cuts power consumption by 10%).

Saving weight of stacker cranes

DUOSYS super-fast mini load AS/RS

The tuning control technology of DUOSYS enables two stacker cranes to function in the same aisle of the AS/RS, moving past each other without interference to perform storage and retrieval operations. The DUOSYS features two tiers, which allows four stacker cranes to operate simultaneously on the same rack producing a maximum storage and retrieval throughput of 2,200 cases per hour. Because of their lightweight design, DUOSYS stacker cranes consume less power than older models performing similar tasks. Also, the system directly controls the movement and speed of each crane in the most efficient manner by directing the closest available stacker crane to perform an assigned task at the most optimized speed. Moreover, the system uses energy generated during braking to power other cranes.

The super-fast DUOSYS

FAC (FA Cart) automatic guided vehicle to reduce environmental impact

Daifuku developed its FAC Series to meet demands for updated, more efficient automatic guided vehicles (replacing AGVs sold between 1986 and 1994). The FAC is the same size as the older vehicle, which allows the main body to be easily replaced with the new model as a single unit. In line with Daifuku's environmental policy, FAC's design effectively uses existing equipment such as magnetic guidance, central control panels, batteries and rechargers. In addition, FAC uses approximately 10% less power than current models due to its lighter weight and power-saving mode feature. This feature automatically turns the power off when the vehicle is stationary.

FAC-10 roller conveyor type AGV

HID-4, with the improved efficiency of a non-contact power supply system

The HID (high-efficiency inductive power distribution technology) non-contact power supply system distributes electricity to moving carriers without contact. It is used in clean rooms for dust-sensitive semiconductor and flat-panel display (FPD) production. The HID-4 controls both voltage amplitude and power distribution time by leveraging two control technologies, called PAM* and PWM.** With these technologies, Daifuku has succeeded in raising power supply efficiency 2.2 times over existing systems. In addition, the HID-4 cuts power loss during distribution by 20% for the entire system. This could lead to lower cleanroom costs by allowing smaller installation spaces and lower energy consumption.

*PAM: Pulse Amplitude Modulation
**PWM: Pulse Width Modulation

Clean Stocker for FPD factories using HID

Reduced weight and wiring of transport system for semiconductor fabs

Daifuku has improved its Cleanway transport system for semiconductor fabs by fitting the guide rails with communication devices. These devices control vehicles and intersections, directing vehicles to diverge or link as needed. As the scale of systems increases so does the length of guide rails, which can total up to several kilometers. Therefore, Daifuku has applied wire-saving technology to the sensors and wiring used in the devices that are fitted to guide rails, as well as in zone controllers. As a result, rail wiring has been decreased 30%, and onsite wiring installation time has also been reduced 30%.

Cleanway
transport system for semiconductor manufacturing fabs

E-DIP increases painting quality and lowers costs

To maintain the paint quality of new vehicles and prevent rust, applying the base coat correctly is particularly crucial. Unlike existing chain conveyor systems, the E-DIP carrier flexibly adjusts the vehicle body angle, while immersing and removing it from the dipping tank. The carrier also appropriately controls the vehicle body, keeping it from swaying in the tank. In doing so, the E-DIP improves the coating quality, reduces liquid lost from the tank by 30%, and helps prevent liquid waste due to inadvertent mixing with other liquids. At the same time, E-DIP reduces the environmental impact and operating costs by using smaller tanks and shorter conveyor lines.