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202 lines
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202 lines
10 KiB
Markdown
---
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title: "Pallet Shuttle"
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type: module
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sources:
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- areas/pallet_shuttle/index.md
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- areas/pallet_shuttle/ps.md
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- areas/pallet_shuttle/ps_user.md
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- areas/pallet_shuttle/agv_ps/index.md
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- areas/pallet_shuttle/agv_ps/agv_ps_extract.md
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- areas/pallet_shuttle/agv_ps/agv_ps_search.md
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- areas/pallet_shuttle/agv_ps/agv_ps_cancel_task.md
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- areas/pallet_shuttle/agv_ps/agv_ps_errors.md
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- areas/pallet_shuttle/agv_ps/ps_battery.md
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- areas/pallet_shuttle/agv_ps/parameters.md
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- areas/pallet_shuttle/ps_user/index.md
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- areas/pallet_shuttle/ps_user/ps_deposit.md
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- areas/pallet_shuttle/ps_user/ps_extraction.md
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- areas/pallet_shuttle/ps_user/ps_compact_location.md
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- areas/pallet_shuttle/ps_user/ps_count.md
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- areas/pallet_shuttle/ps_user/ps_status.md
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- areas/pallet_shuttle/ps_user/ps_special_func.md
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- areas/pallet_shuttle/ps_user/ps_configuration.md
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- areas/pallet_shuttle/ps_app/index.md
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- areas/pallet_shuttle/ps_app/ps_app_deposit.md
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- areas/pallet_shuttle/ps_app/ps_app_extraction.md
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- areas/pallet_shuttle/ps_app/ps_app_compact_location.md
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- areas/pallet_shuttle/ps_app/ps_app_PSDiagnosis.md
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- areas/pallet_shuttle/ps_app/ps_app_manual_mode.md
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- areas/pallet_shuttle/views/pallet_shuttle.md
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related:
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- modules/agv.md
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- concepts/location.md
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- concepts/container.md
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- concepts/task.md
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- concepts/stations.md
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last_compiled: "2026-04-10"
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---
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# Pallet Shuttle
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## Overview
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The Pallet Shuttle module integrates motorized container transport carts (pallet shuttles) into Easy WMS warehouse operations. A pallet shuttle is a WIFI-controlled cart that moves autonomously within the deep channels of compact racking systems, transporting containers to and from the channel entrance without requiring a forklift to enter the aisle.
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Each pallet shuttle operates in one of two storage modes:
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- **LIFO** (Last In First Out): loading and unloading always at the same channel end
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- **FIFO** (First In First Out): loading from one end, unloading from the other
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The module eliminates the need for forklifts to reach deep positions, dramatically increasing storage density and reducing travel time. Operators control the shuttle via a tablet (SmartUI workstation or native app), while Easy WMS manages the stock movements. When the AGV module is also installed, pallet shuttle transport between channels is automated.
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## Key capabilities
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- Container deposit and extraction in compact rack channels (LIFO and FIFO modes)
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- Channel compaction (push containers toward front or back for space optimization)
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- Inventory count directly from the pallet shuttle interface
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- FIFO mode: automatic inversion detection (cart orientation tracked)
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- Battery management: automatic dispatch to charging station when low; auto-retrieval when full
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- AGV integration: automated PS relocation between channels without manual forklift intervention
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- Multi-site support: same PS can be registered in two different warehouses (for shared PS in multi-site)
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- Two control interfaces: SmartUI workstation (browser-based) and native tablet app (Windows UWP / iOS / Android)
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## Architecture
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### Pallet shuttle types
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Each PS hardware model is registered as a **pallet shuttle type** with:
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- Version (firmware)
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- Horn (for locating lost carts by sound)
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- Camera (assists forklift operators with placement)
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- Electromagnet (attaches to forklift forks for safe transport - required for AGV integration)
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- Maximum weight and compatible container types
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- Container type mapping (PS internally uses A, B, C… labels; mapping to WMS container types required)
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### PS attributes
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| Field | Description |
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|-------|-------------|
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| Number | Identifies the PS (labeled on the cart) |
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| IP address (PLC) | Network address for WMS communication |
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| IP address (camera) | Camera communication address |
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| Status | Available, faulty, mode, etc. |
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| Current task | Extraction, deposit, compacting, etc. |
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| Last known location | Last confirmed location of the cart |
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| Input aisle | For FIFO channels: the entry aisle code |
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| Estimated battery charging time (min) | 0–300; empty if not charging |
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### PSService
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A service called **PSService** centralizes communication between tablets and the physical pallet shuttles. Both the SmartUI workstation app and the native tablet app use this service. **Note**: the two modes are mutually exclusive - the service is configured for either SmartUI or the native app, not both simultaneously.
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### Native app modes
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- **Simple mode**: tablet → PSService → pallet shuttle (recommended for full WMS integration)
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- **Multi mode**: tablet communicates directly with PS (no WMS integration of stock movements)
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## Configuration
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1. Configure compact rack locations with appropriate storage mode (LIFO or FIFO) in EasyS/EasyAssistant
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2. Register pallet shuttle types with container type mappings
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3. Register individual pallet shuttles (IP, PLC, camera, type)
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4. Install and configure PSService (see implementation documentation)
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5. For AGV integration: configure AGV module, create routes between PS locations and AGV stations
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### Key parameters (AGV-PS integration)
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| Parameter | Default | Description |
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|-----------|---------|-------------|
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| `PS_MAX_MINUTES_BATTERY_FULL_LOAD` | 300 | Minutes of charging before battery considered 100% |
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| `PS_MIN_MINUTES_BATTERY_LOAD` | 90 | Minimum minutes charged before PS can be dispatched to tasks |
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## Operations
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### Manual operation (SmartUI workstation or native app)
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**Deposit (putaway)**
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- **Simple deposit**: one container → placed at deepest available position
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- **Continuous deposit**: multiple containers sequentially into same channel; PS compacts after each
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- Putaway strategies must prevent mixing different items in the same channel
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**Extraction**
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- **Simple extraction**: one container → brought to channel entrance
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- **Continuous extraction**: sequential extraction of multiple containers
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- Abort action stops PS immediately and deposits load at current depth
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**Compaction**
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- **LIFO Compaction to outbound**: pushes all containers toward channel entrance (faster extraction)
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- **LIFO Compaction to inbound**: pushes all containers to channel back (maximizes entry space)
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- **FIFO Compaction**: pushes to extraction end (FIFO correctness and capacity maximization)
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- After physical compaction, operator must register the compaction in WMS to update available space
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**Special functions**
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- Change last known location (if PS was moved manually)
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- Send PS to charging station (manual override via "Send PS to charging station" action)
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- Extract PS from charging station (manual via "Extract PS from charging station" action)
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### AGV-PS integration operations
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**PS search algorithm (when no PS is in a required channel)**
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Search criteria (all must be met):
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1. PS is activated and connected
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2. Mode is automatic
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3. Not on low battery
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4. Not linked to active receiving/shipping locations
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5. Not assigned to equipment
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6. Not in failure state
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7. Priority: closest to the target location
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**PS transport flow** (load type = `1`, electromagnet activated at phase 06, deactivated at phase 10):
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- WMS sends PS transport order
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- AGV system accepts (00) → assigns AGV (03) → requests load permission (04)
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- WMS verifies PS is at load location → sends load auth
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- AGV confirms load (06) - electromagnet activated
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- AGV confirms unload (10) - electromagnet deactivated, new PS location reported
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**FIFO specifics**: PS can be extracted from either end of channel. System tracks orientation (`inverted signal` field) to ensure correct placement direction.
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**Error flag reset**: When AGV extracts/deposits a PS, error flags (tilt, fault) are reset and checked. If error persists after reset, all tasks for that PS are canceled and user is notified.
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### Background jobs (AGV-PS mode)
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| Job | Interval | Purpose |
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|-----|----------|---------|
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| Search waiting AGV tasks | 10s | Send pending tasks to AGV system |
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| Search fully charged PS | 5min | Extract PS from charging station when needed |
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| Search low battery PS | 10s | Dispatch low-battery PS to charging station |
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| Search tasks pending unload | 10s | Retry tasks stuck at unload permission |
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| Search tasks pending load | 10s | Retry tasks stuck at load permission |
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| Search channels with first position occupied | 10s | Execute deposit tasks for PS with waiting containers |
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### Battery management
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**Automatic (AGV required)**:
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- Low battery flag → WMS creates AGV task → PS transported to available charging station → charging time counter starts at 0 and counts to 300 (minutes)
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- Full charge (300 min, configurable via `PS_MAX_MINUTES_BATTERY_FULL_LOAD`) → AGV task created to extract PS **if** another PS needs the station or there are pending tasks with no other PS available
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- Minimum charge (`PS_MIN_MINUTES_BATTERY_LOAD` = 90 min) → PS can be extracted early if urgently needed
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**Manual** (web interface, Pallet Shuttles view):
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- "Send PS to charging station" action (available when PS is not already at a charging station)
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- "Extract PS from charging station" action (available for PS at charging location)
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## Errors & troubleshooting
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### PS error indicators (AGV context)
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- **Fault flag**: Caused by multiple reasons. Reset → retry. If flag re-activates: all PS tasks canceled, user notified, PS unavailable for new tasks
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- **Tilt error**: PS mispositioned in channel. Reset → retry. Same cancellation behavior if persistent
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- **Low battery**: PS completes current tasks → returns to pickup position → disconnects → awaits AGV dispatch to charging. If no charging station available: user notified
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### Extraction error (AGV picks up PS)
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Task canceled; location marked with "For AGV" lock type; user notified. No container relocation (PS was the payload, not a container).
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### Putaway error (AGV deposits PS)
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Task canceled; PS relocated to available location with no pending tasks; location marked with "For AGV" lock type; user notified.
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### Cancellation of AGV-PS tasks
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- **Task pending (waiting/pending shipping with CREATE action)**: Can be canceled - AGV system not yet involved
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- **Task in process (any other state)**: Cannot be canceled - movement will complete at destination
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## Related
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- [[agv]] - AGV module handles automated PS transport; all PS movements with AGVs use AGV task infrastructure
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- [[location]] - Compact rack channels (multi-deep) are the PS's operating environment; LIFO/FIFO mode per location
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- [[container]] - PS transports containers within channels; simple/continuous deposit and extraction
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- [[task]] - PS operations generate WMS tasks (putaway, extraction) tracked in the standard task system
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- [[stations]] - PS charge stations (type 66, PSCharge), PS type station in warehouse layout
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