# 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 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 the racking front frame (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** – 820 × 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** – 1200 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. Stations
- **One per robot** – At the end of each robot aisle, where the robot presents bins for picking and putaway
- **Integrated weight verification** – Platform scales confirm pick accuracy and catch overweight items
- **Zones** – A block of three or four robot aisles is served by one operator with one put-to-light trolley; the operator moves between the zone's stations as bins arrive
- **Throughput per operator** – Up to 300 bin presentations per hour with batch picking

### 5. Put-to-Light Trolley
- **Batch picking** – A 3 m put-to-light trolley behind the operator holds the zone's open orders, one shipper per position, so one presented bin serves several orders at once
- **Put to light** – The app shows the quantity to pick; one position lights at a time to show where to put it, eliminating picking errors
- **Scan to bind** – The runner scans each fresh shipper into a freed position; the system binds it to the next order and tracks completion
- **Batch optimization** – System optimizes order assignment and robot dispatch to keep all robots continuously working
- **Completed order swap** – When a position shows complete, the runner lifts the shipper onto the takeaway and places a fresh shipper of the size called; the operator keeps picking throughout

### 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 orders to the open positions on each zone's trolley and optimizes robot dispatch
3. **Shipper induction** – Runner places a fresh shipper of the size called in a freed position and scans it; the system binds it to the order
4. **Station direction** – System directs operator to next ready station
5. **Source bin delivery** – Robot delivers source bin containing required SKUs to station
6. **Sequential putting** – Put-to-light lights one shipper position at a time with the quantity needed
7. **Pick confirmation** – Operator scans the item and places it in the lit shipper position; weight verification confirms accuracy
8. **Source bin return** – Operator initiates robot return when source bin complete
9. **Order completion** – When the order is fully picked the position lights complete; the runner swaps the shipper onto the takeaway for packing and dispatch
10. **Inventory update** – System updates inventory levels and notifies WMS

### 3. Putaway
- **Manual putaway** – Operator scans items into bins at the station
- **Auto empty-bin flow** – System detects empty bins and routes them for putaway
- **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 (the put-to-light trolley keeps all robots continuously working)
- **Add aisles** – Expand storage capacity by adding more racking aisles
- **Add operators** – Each operator with a put-to-light trolley 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

This page and its companions ([Technical Data Sheet](/docs/technical-data-sheet),
[Safety & Compliance](/docs/safety-compliance), [Integration](/docs/integration),
[Example Configurations](/docs/example-configurations)) are conceptual
introductions. The engineering source of truth is the
**[published documentation](/documents)** - the racking, electrical, data
dive and other specifications - which is versioned and always current.
Where a number here and a number in a published specification disagree,
the specification wins.

## What's Not Covered Here

These docs are **not** operational manuals. For day-to-day operation, training, and troubleshooting:
- **User Manual** – Operator workflows, pick/putaway 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 [Technical Data Sheet](/docs/technical-data-sheet) to understand planning ranges
- Send us your SKU master + order history for a custom sizing ([contact us](/contact))
- Book a site check to verify racking, electrical, and access requirements

**If you're planning an installation:**
- Review [Racking Specification](/docs/racking-specification) and [Electrical Specification](/docs/electrical-specification)
- 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](/docs/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 →](/docs/technical-data-sheet) | [Get a site check](/contact) | [Integration overview →](/docs/integration)