Arthur Ria
20 KiB
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2026-04-17 |
Stations & Routes
Overview
Stations are the structural start and end points of all container movement in the warehouse. In automatic warehouses, they form the basic interconnection layer between Easy WMS and the Transport Management System (TMS). Every task generated by the system is a movement from a source station to a destination station along a defined route.
A critical design principle: minimize the number of stations. More stations means more communication nodes, more possible delays, and higher risk of bottlenecks. Create only what is strictly necessary for optimal container flow.
Each station has:
- A type (determines behavior and process)
- A capacity (max containers simultaneously heading to that station)
- An optional process type (restricts which task types pass through it)
Station Types Reference
Easy WMS defines 37+ standard station types. Types are identified by a numeric code.
Storage Stations
| Code | Type | Name | Description |
|---|---|---|---|
| 0 | ALM | Warehouse | Set of storage locations (shelves, ground locations, any storage element). Not connected to TMS — no machine communication. Involved in: location (destination), extraction (source), transfer (source+destination). Can be configured to allow/deny inbounds or outbounds independently. |
Inbound / Conveyor Stations (AS/RS)
| Code | Type | Name | Description |
|---|---|---|---|
| 3 | PIE | Pallet Check Unit | Dimensional + identification control of containers. TMS sends height, weight, status, and label data to Easy WMS. Easy WMS validates and routes: correct → warehouse; wrong → REAC/RECH. All stations with a gauge arch or scale must be configured as PIE. PIE events evaluate flags: 65536=correct, 256=barcode error, 512=recovered container, 1024/66560=correct+empty, 3=holes+studs, 4=overheight, 8–64=overhangs, 128=weight excess. |
| 9 | ME | Aisle Inbound Conveyor | Interchange point with AS/RS (TRASLO). Final optimization before container enters the machine. Checks stacker crane characteristics (number of extractors, conveyors). If container arrives at ME with both putaway and picking tasks, putaway is cancelled and container goes to picking. Final location decision point — refines but doesn't replace initial search. Required in all automatic warehouses with stacker cranes. |
| 10 | MS | Outbound Conveyor | AS/RS unload point — where the machine unloads an extracted container onto the conveyor. Not mandatory (in Galileo IV the location is freed at AS/RS loading), but recommended for additional control, ring saturation prevention, and movement statistics. Taskless containers (order cancelled) return to vault. |
| 11 | MU | Putaway Conveyor | Searches for a putaway location by applying configured strategies. Only acts on containers without tasks or containers whose destination task points to this station. Useful when PIE is far from the warehouse — PIE skips location search, MU refines it just before warehouse entry. If problem generating movement: movement generated with origin=destination, flagged "With conflict"; cleared when possible. |
| 13 | APL | Stacker / Unstacker | Handles stacking and unstacking operations for empty containers. |
| 14 | LANZ | Shuttle | Shuttle station for Pallet Shuttle operations. |
| 18 | PKE | PK Inbound Conveyor | Entry to the picking inbound conveyor. |
| 62 | Lift | Lift | Lift station for multi-level operations (APS3D carts change level through this). |
AS/RS Machine
| Code | Type | Name | Description |
|---|---|---|---|
| 1 | TRASLO | AS/RS | Automated Storage/Retrieval System — the crane or machine. Bidirectional: loads from ME (inbound), unloads into MS (outbound). Communication via protocol (Galileo IV supports loading event + location release simultaneously). |
Picking Stations
| Code | Type | Name | Description |
|---|---|---|---|
| 2 | PK | Picking Conveyor | Managed from the "Picking" view. Operator is guided: what to pick, how much, where to put it. Supports multiple locations per station (multiple containers simultaneously). Operations: direct picking, container/item count, replenishments. Can have associated RECH reject station. Empty container removal requires location configured for empty container handling. |
| 4 | PS | Outbound Conveyor | Final point of automatic transport — container leaves the warehouse. Management cycle of Easy WMS ends here (no more tasks). May have a display panel showing operator where to carry the container. Location types: Dynamic (Easy WMS tracks container depth) or Automatic (Easy WMS knows only which container is on PS, not which follows). |
| 16 | MP | Preparation Zone | Zone for order preparation — used in semi-automatic picking operations. |
| 17 | Consolidation | Consolidation Station | Consolidation station for grouping picked stock by shipping order. |
| 53 | PCS | Sequencing Control Point | Point where order sequencing is controlled in the transport flow. |
| 54 | PB | Proximity Buffer | Buffer near a picking station to temporarily hold containers. |
| 60 | TenseFlow | Tense Flow | Station for tense-flow operations (continuous uninterrupted picking flow). |
| 63 | Decision (DS) | Decision Station (Pick and Pass) | PopUp element at intersection of main transport and sub-warehouse routes. Analyzes: is container a client container? Is it full? Does it have pending tasks in this sub-warehouse? Does it have putaway tasks here? On failed read: reject task to error entity station. Location containers without approach task access first station of transport route. Client containers without approach task: flow generates approach task to destination sub-warehouse. |
| 64 | Workzone (WS) | Workzone Station (Pick and Pass) | Automatic buffer element at entry of each sub-warehouse. Worker picks up/drops off containers. Required for picking start points per sub-warehouse. Has "Sequence" parameter for logical ordering along transport flow. Locking prevents approach tasks from being created (blocks sub-warehouse access). |
Control / Maintenance Stations
| Code | Type | Name | Description |
|---|---|---|---|
| 5 | REAC | Reconditioning | Destination for containers that fail PIE validation but can be corrected and re-injected into the flow. |
| 7 | RECH | Rejects | Destination for definitively rejected containers — not reintegrable. |
| 20 | ET | Transit Station | Intermediate station inserted in routes to break task flow. Does not perform any WMS management — designed for flexibility and external system integration (robotic arm, labeling machine, vertical warehouse, etc.). For automatic locations: only one container at a time (new arrival sends previous to Lost & Found). For non-automatic (buffer) locations: multiple containers allowed. TMS must always report aisle=1 in station update. |
| 21 | CME | Inbound Control Station | Control point for inbound conveyors. |
| 42 | RETENTION | Retention | Retention station — holds containers that require manual review or authorization before continuing their route. |
| 43 | DESK | Desk | Desk station for administrative or manual operations. |
| 55 | ECB | Empty Containers Buffer | Buffer specifically for empty containers waiting to be stacked or reused. |
| 58 | ETQ | Labeller | Labeling machine station — container passes through and is automatically labeled. |
Dock & Stage Stations
| Code | Type | Name | Description |
|---|---|---|---|
| 33 | Stage | Stage (Shipping/Receiving) | Floor area for temporary stock storage, typically near docks. Receiving stages: for stock pending putaway. Shipping stages: for client containers awaiting truck load. One of each can be set as default. Locations are DockStage type — Easy WMS does not control exact container position. Capacity = 0 means unlimited. Cannot be used for putaway; cannot generate tasks from stage (only from warehouse-type locations). |
| 33 | PKS | Packing Station | Packing station for packaging operations (shares type code 33 with Stage). |
| 34 | Dock | Dock | Point of receipt or shipping. Types: inbound dock, outbound dock, or combined. At least one must be configured. Locations are DockStage type. No exact position tracking. Route must exist (even indirect) from container location to dock for task generation. Multiple locations per dock supported. |
Special / Module Stations
| Code | Type | Name | Description |
|---|---|---|---|
| 38 | Kit | Kits Assembly | Station for assembling kit items. |
| 57 | CONVEYOR | Conveyor (eCommerce) | Conveyor station for eCommerce operations — container-based order consolidation. |
| 59 | VAS | VAS Conveyor | Conveyor station for executing Value Added Services. |
| 61 | Cutting | Cutting Station | Station where cutting stock is cut in integrated or delegated picking processes. Composed of a receiving stage and a shipping stage (configurable: 1 shared stage, 2 dedicated stages, or shared stages across multiple cutting stations). Can be locked via "Stations" view to prevent stock assignment. |
| 65 | AGV | AGV Station | AGV robot station. |
| 66 | PS Charge | PS Charge | Pallet Shuttle charging station. |
| 0 | Fleet Manager | APS3D Fleet Manager | Manages carts (APS3D) across all aisles and levels. Periodically requests tasks from Easy WMS, assigns to carts, informs of completion. Configuration: code, station number (unique per type+warehouse), sub-warehouse, work mode (Input/Output/Combined/Disabled), sequence level (Stricted). Behavior similar to AS/RS type. |
Multi-Role Stations
A single physical station can have more than one role, enabling context-sensitive behavior:
PIE with multiple roles: A PIE station configured as a rejection or reconditioning station simultaneously. The workstation view updates to show the appropriate interface (PIE vs RECH/REAC) based on the container's task. Configuration: arrange both stations in EasyS, create PIE→RECH/REAC route, add RECH/REAC as Error Entity for PIE. Then assign role in SmartUI "Stations" view via "Assign new role".
PK with multiple roles: PK station acting also as a reject station. When a container is rejected at PIE, the target reject station is the PK that originally handled the container — enabling workload balance and operator accountability. No SmartUI role assignment needed. Configuration: arrange PK+RECH in EasyS, create route, add RECH as Error Entity for PK. Special case: if no dedicated reject station exists, PK itself can be the PIE's error entity.
Station Code Translation (FR / ES / EN)
Mecalux teams work across three languages; the same station can appear in logs and documentation under different codes. Canonical cross-reference (see Mechanical Elements for the full table including acronyms):
| Type | Code FR | Code ES | Code EN | Description (FR) |
|---|---|---|---|---|
| 0 | MAG | ALM | AIS | Magasin |
| 1 | ML / TK | TRASLO | STC | Miniload / Transstockeur |
| 2 | PK | PK | PK | Poste de picking |
| 3 | PIE | PIE | EIP | Poste d'identification d'entrées |
| 4 | PS | PS | SC | Poste de sortie |
| 9 | TE | ME | IC | Table d'entrée |
| 10 | TS | MS | OC | Table de sortie |
| 11 | MU | MU | MU | Table de recherche d'emplacement |
| 16 | TP | MP | MP | Table de préparation |
| 18 | PKE | PKE | PKE | Poste d'entrée au PK |
| 20 | ET | ET | TS | Station de transit |
| 21 | CME | CME | ICS | Contrôle d'entrée au magasin |
Station Capacity Semantics (GALILEO view)
Station capacity has a different meaning on PK and PS than on other stations — this trips up Gateway log analysis.
| Layer | Generic station (conveyor/TK) | PK and PS |
|---|---|---|
| Physical capacity | Containers that fit on the physical station | Containers that fit on the physical station |
| Route capacity | Containers in transit on upstream conveyors | Containers in transit on upstream conveyors |
| WMS capacity | Same as physical | Physical + transit + every task whose destination is this station |
Worked example (PK): 1 physical slot + 4 in transit on intermediate conveyors + all pending tasks targeting PK = 15 is the value that appears in the WMS capacity.
Route configuration in EasyS (robotics)
In robotics installations, every movement between automated stations requires a route in EasyS. A single task (e.g. PIE → Miniload) can generate N movements (4 is typical) — the WMS creates one task, the routing table allows each hop.
If no path exists, EasyWMS creates a reject task toward the configured reject station.
Route inventory: Menu → Control → Itineraries between stations.
EasyS route types (cross-reference with Manager table below):
| EasyS type | Use case |
|---|---|
| Galileo | Requires Gateway calls (physical hop) |
| Manual | Operator action triggered by a WMS task |
| Virtual | Instantaneous automatic movement (e.g. output → consolidation) |
Reject routes (in red) are special: they give the task destination (not the movement destination). Different IdentError reasons can target different reject destinations — see IdentErrorType.
For the protocol layer and message exchange (Search / End / Event / station updates), see GALILEO Integration. For bring-up and simulation, see Galileo Simulation.
Routes
A route defines the path between two stations. Route types:
- Simple route: Direct A → B with no intermediate stations. Known by both Easy WMS and TMS.
- Composed route: A → B → C → ... → N, built from multiple simple routes. Known only by Easy WMS (TMS handles individual simple routes). Result: task = composed movement; movement = simple route.
Easy WMS generates tasks based on configured routes. Before generating a task, it checks:
- That a route exists between source and destination.
- That the route is active (all stations in route are not locked).
Exception: shipping full containers via dock — only checks that a route exists, not whether it's active.
If the shortest active route is blocked, Easy WMS immediately tries an alternative route.
Route distance: Can be configured in EasyS. Easy WMS prefers shortest path.
Route Managers (Executors)
Each simple route requires a declared manager — the type of element that will execute tasks on that route:
| Manager | Executor |
|---|---|
| Galileo | Automatic element (conveyor, machine) |
| Monorail | Monorail system |
| RF | Operator with RFT (radio frequency terminal) |
| Voice | Operator with voice terminal |
| Virtual | Automatic — task auto-completes when container arrives at source station, no physical action |
| PTL | Pick-to-Light system |
| External | External system (AGV, vertical warehouse, ERP, etc.) |
| APS3D Fleet Manager | APS3D cart system |
Route Incidences
| Incidence | Description | Resolution |
|---|---|---|
| Container without task at station | Container arrives at a station in an automatic warehouse when its task was cancelled | Manual intervention: reassign or send to staging |
| Disabled route | A route has been disabled | Enable route or create alternative route |
| Destination station loaded | Destination station has containers on it exceeding capacity | Wait or redirect |
| Destination station in default | Destination station is down/faulted | Repair station, activate alternative route |
| Destination/intermediate station locked | A station on the route is locked | Unlock station or activate alternative route |
Dock & Stage Configuration (SmartUI)
Docks and stages are created in EasyS (or Warehouse Designer), not in SmartUI. SmartUI provides read/edit/action access.
Dock/Stage attributes: Code, abbreviation (used for PTL picking destination display), description, station type, warehouse, by-default for receipts/shipping, capacity, work mode (receipts/shipping/both), lock status.
Actions available:
- Lock / Unlock
- Set as default for receipts or shipping (removes previous default if set)
- Set capacity (wizard)
- Set work mode
- Set abbreviation (for PTL display)
- Print labels (format + copies)
- Assign printer (report printer and/or label printer, or "Do not print")
- Audit
Work mode values: Receipts, Shipping, Both.
Interface
- Stations configuration: "Stations" view in the "Control" menu (PC)
- Routes between stations: "Routes between stations" in the "Control" menu (PC)
- Docks and stages master: "Docks and stages master" in the "Control" menu (PC)
- Station status (3D map): Warehouse Map → click station → view capacity, occupation, work mode
Common Errors
| Error | Cause | Solution |
|---|---|---|
| No task generated for container | No active route from source to destination | Check route exists and all intermediate stations are unlocked |
| Container stuck at MS with "With conflict" flag | Downstream route blocked (MS can't generate movement) | Identify and resolve the blocked station/route; system auto-recovers |
| PIE rejecting all containers | Incorrect flag configuration or gauge mismatch | Verify PIE event flags, check container dimensions vs gauge arch tolerance |
| Container sent to Lost & Found at ET | Two containers at same automatic ET location simultaneously | Check TMS event ordering, ensure only one container per automatic ET location |
| MU not finding location | No putaway strategy active for container/item | Verify putaway strategy configuration; ensure route from MU to warehouse exists |
Related
- location — Location types associated with each station (DockStage, buffer, conventional)
- task — Every movement is a task; tasks decompose into simple route movements
- warehouse-designer — Stations are created in EasyS/Warehouse Designer, transferred to SmartUI
- picking — PK, MP, Workzone, Decision, PKE, TenseFlow, Consolidation all support picking
- reception — Dock, Stage, PIE stations are central to receiving workflows
- shipping — Dock, Stage, PS, Consolidation stations support outbound flow
- putaway — PIE triggers location search; MU refines it closer to warehouse