System Overview

Shelfbot is a Goods-to-Person warehouse automation system that uses autonomous robots to retrieve storage bins from standard racking and deliver them to operators at pick stations. The system retrofits into existing AS4084-compliant steel storage racking and integrates with your WMS via REST API.

Key principle: We built Shelfbot to be simple to understand, simple to operate, and simple to maintain—without sacrificing performance.

What Shelfbot Is

Shelfbot delivers the storage density and throughput of enterprise ASRS without the proprietary grids, 12-month implementations, or multi-million dollar commitments. It’s designed for warehouses that need automation but can’t afford the complexity or capital of traditional systems.

Core capabilities:

• Goods-to-Person picking (bins delivered to operators, not vice versa)
• 4× storage density improvement vs. manual operations
• 5× faster order picking vs. manual
• 4–8 week deployment (not 6–18 months)
• Robots as a Service (RaaS) model from $10,000/month

System Components

1. Robots

• Autonomous navigation – Robots travel horizontally on rails and move vertically within racking aisles
• No batteries – Powered via 240V mains supply from outlets on racking uprights (no downtime for charging)
• Payload – 20 kg max bin weight
• Speed – Up to 2,500 mm/s horizontal; vertical lift speeds optimized for safety and throughput
• Per-robot throughput – 60 bin presentations per hour

2. Bins

• Standard dimensions – 720 × 420 × 285 mm (L × W × H)
• Material – Plastic bins (standard); steel fire-rated bins available
• Items per bin – Depends on SKU dimensions; typically 5–50 items depending on product size
• Bins per level – 5 bins per shelf level (typical configuration)

3. Racking

• Standard steel racking – AS4084:2023 compliant storage racking (not proprietary grids)
• Aisle width – 940–950 mm
• Height range – 4–10 m (up to ~21 levels at 10 m height)
• Aisle length – Up to 48 m (18 bays)
• Key advantage – Uses existing racking or standard racking suppliers; no proprietary infrastructure

4. Pick Stations

• Fixed picking locations – Positioned at aisle ends where robots deliver source bins
• Integrated weight verification – Platform scales confirm pick accuracy and catch overweight items
• Multiple stations per aisle – Operators move between stations for batch picking efficiency
• Throughput per operator – Up to 300 bin presentations per hour with batch picking

5. Pick Wall

• Mobile batch picking – 12-bin mobile pick wall enables operators to pick multiple orders simultaneously
• Sequential pick-to-light – One bin lights up at a time with quantity, eliminating picking errors
• RFID bin tracking – Automatic detection when bins added/removed, assigns orders and tracks completion
• Batch optimization – System optimizes order assignment and robot dispatch to keep all robots continuously working
• Multi-bin orders – Orders can span multiple bins when needed; operator can request additional bins

6. Server & Software

• On-premises server – Manages robot orchestration, bin locations, and WMS integration
• REST API – Secure API connects to your existing WMS, ERP, or e-commerce platform
• Real-time inventory sync – Product data, inventory levels, and order transactions synchronized via documented endpoints
• Cloud redundancy – System state backed up for disaster recovery

How It Works

1. Inventory Storage

• Products are stored in bins on standard steel racking
• Each bin is assigned a unique ID and tracked by the system
• Multiple SKUs can share a bin, or SKUs can span multiple bins
• Bins are stored at high density across multiple aisle levels

2. Order Processing Flow

1. Orders received – WMS sends orders to Shelfbot via API
2. Batch optimization – System assigns up to 12 orders to operator’s pick wall bins and optimizes robot dispatch
3. Bin assignment – Operator places order bins on pick wall; RFID detects and assigns orders
4. Station direction – System directs operator to next ready pick station
5. Source bin delivery – Robot delivers source bin containing required SKUs to pick station
6. Sequential picking – Pick-to-light illuminates one order bin at a time with quantity needed
7. Pick confirmation – Operator scans item and places in lit bin; weight verification confirms accuracy
8. Source bin return – Operator initiates robot return when source bin complete
9. Order completion – When order fully picked, operator removes bin from pick wall; RFID marks order ready for packing
10. Inventory update – System updates inventory levels and notifies WMS

3. Replenishment

• Manual replenishment – Operator scans items into bins at the pick station
• Auto empty-bin flow – System detects empty bins and routes them for replenishment
• FIFO support – System can prioritize older inventory for picking (first-in, first-out)

4. Scaling

• Add robots – Increase throughput by adding more robots to existing aisles (pick wall keeps all robots continuously working)
• Add aisles – Expand storage capacity by adding more racking aisles
• Add operators – Each operator with pick wall can handle up to 300 bin presentations per hour
• No system redesign required – Scale incrementally without rebuilding infrastructure

Who These Docs Are For

Operations Managers

• Evaluating whether Shelfbot fits your operation
• Understanding throughput, storage density, and ROI
• Planning deployment timelines and operational changes

Engineers & Technical Teams

• Designing installations and integration points
• Reviewing electrical, racking, and environmental requirements
• Understanding API integration and data exchange

Electricians & Fire Consultants

• Planning electrical supply and circuit protection
• Reviewing fire safety compliance and sprinkler requirements
• Understanding safety interlocks and guarding

Procurement & Finance Teams

• Understanding capital vs. operational costs (RaaS model)
• Reviewing commercial terms and service agreements
• Planning budget allocation and payback timelines

Documentation Structure

These docs are organized to match your evaluation and implementation workflow:

1. System Overview (this page) – Conceptual understanding
2. Specs & Site Requirements – Planning ranges, performance, and prerequisites
3. Racking Specification (PDF) – Detailed racking requirements
4. Electrical Specification (PDF) – Power supply, circuit protection, and installation
5. Safety & Compliance – Risk assessment, guarding, and regulatory compliance
6. Integration – API, WMS integration, and data requirements
7. Example Configurations – Real-world system designs
8. Evaluator Pack – Quick-start evaluation guide

What’s Not Covered Here

These docs are not operational manuals. For day-to-day operation, training, and troubleshooting:

• User Manual – Operator workflows, pick/replenish procedures, and troubleshooting
• Commissioning Manual – Installation and commissioning procedures (provided to installers)
• API Documentation – Endpoint specifications, authentication, and integration guide

Next Steps

If you’re evaluating Shelfbot:

• Read Specs & Site Requirements to understand planning ranges
• Send us your SKU master + order history for a custom sizing (contact us)
• Book a site check to verify racking, electrical, and access requirements

If you’re planning an installation:

• Review Racking Specification (PDF) and Electrical Specification (PDF)
• Share site plans with us for validation
• Engage a fire consultant for sprinkler and compliance review

If you’re integrating with your WMS:

• Review Integration for API requirements
• Confirm your WMS has documented APIs for products, inventory, and orders
• Schedule a technical integration workshop with our team

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Specs & site requirements → | Get a site check | Integration overview →