Four-Way Shuttle Rack System – The Future of Fully Automated Warehousing

What Is a Four-Way Shuttle Rack System?

The Four-Way Shuttle Rack System is an advanced automated storage and retrieval system (ASRS) that integrates:

• Four-way shuttle robots
  
• Conveyor networks and vertical lifts
  
• Specialized high-density racks
  
• Smart warehouse management software (WMS/WCS/WES)
  

Unlike the Two-Way Shuttle system, the four-way shuttles can travel in all directions, allowing unrestricted pallet access, flexible layout design, and seamless warehouse expansion without structural changes.

Each shuttle operates at speeds up to 1.5 m/s (unloaded) and 1.2 m/s (loaded), handling loads between 500–1,500 kg per pallet, running 24/7 with real-time system coordination through Siemens PLC and Vinatech’s intelligent control software.

System Architecture

1. Four-Way Shuttle Robots

• Load capacity: 500–1,500 kg per pallet
  
• Speed: 1.5 m/s (unloaded), 1.2 m/s (loaded)
  
• Power: 48V lithium battery, 7–8 hours continuous operation
  
• Temperature range: 5°C–45°C (custom versions for cold storage)
  
• Movement: Full 4-direction travel for optimal route efficiency
  
• Communication: Wireless link with WMS/WCS for instant coordination

2. Conveyor System

Handles pallet flow between storage, lifts, and outbound zones.
Includes automatic check stations for:

• Weight verification
  
• Dimension scanning
  
• Barcode/QR code reading
  
• Auto-reject for out-of-spec goods
  

3. Lift System

Vertical lifts transport shuttles and pallets between rack levels.

• Speed: 0.5–1 m/s
  
• Precision: ±2 mm
  
• 24/7 continuous operation with smart task scheduling

4. Warehouse Software Suite

• WMS (Warehouse Management System): Oversees inventory, storage positions, and order processing.
  
• WES (Warehouse Execution System): Coordinates real-time task distribution and load balancing.
  
• WCS (Warehouse Control System): Directly controls hardware—shuttles, conveyors, and lifts—for accurate execution.
  

Automated Workflow (6 Steps)

1. Receiving: Pallets enter via forklifts, AGVs, or AMRs. The system automatically checks weight, dimensions, and barcode data.
   
2. Lifting: The vertical lift moves pallets to designated rack levels.
   
3. Shuttle Transfer: The four-way shuttle receives instructions from WCS and travels directly to the assigned storage location.
   
4. Storage: The shuttle lifts, places, and records pallet data in WMS in real time.
   
5. Retrieval: Upon order request, the shuttle retrieves the correct pallet and transfers it to the conveyor for dispatch.
   
6. Auto-Charging: When the battery runs low, the shuttle autonomously returns to a charging dock without human intervention.
   

Core Advantages

1. Maximum Space Utilization

• 85–90% storage density, eliminating forklift aisles.
  
• Optimized for both horizontal and vertical expansion.
  

2. Superior Efficiency

• 5–7× faster throughput than manual operations.
  
• Intelligent AI routing minimizes travel distance and waiting time.
  

3. Fully Automated Operation

• Reduces labor costs by up to 80%.
  
• Continuous 24/7 unmanned operation with minimal downtime.
  
• Error rate <0.1% through automated inspection and barcode tracking.
  

4. Flexible & Scalable

• Add more shuttles as demand grows without layout changes.
  
• Supports multi-level, large-scale warehouses and cold storage environments.
  

5. Safety & Accuracy

• No forklifts or workers inside storage aisles → zero collision risk.
  
• Real-time inventory visibility and traceable pallet movement.
  
• Seamless integration with ERP/SAP and IoT systems.
  

Comparison with Other Systems

Criteria	Four-Way Shuttle	Two-Way Shuttle	ASRS	Drive-in Rack
Storage Density	85–90%	80%	90–95%	70%
Throughput Speed	Very High	High	Very High	Low
Investment Cost	High	Medium	Very High	Low
Automation Level	Fully Auto	Semi-Auto	Fully Auto	Manual
Scalability	Excellent	Good	Average	Poor
ROI	3–5 years	2–4 years	5–7 years	N/A
OPEX	Very Low	Low	Very Low	High

Ideal Applications

• National distribution centers (e-commerce, FMCG, logistics hubs).
  
• Large-scale manufacturing (automotive, electronics, pharmaceuticals).
  
• Cold storage facilities (seafood, frozen food, cold logistics).
  
• 3PL/4PL providers requiring ultra-fast, high-accuracy operations.
  
• Digital transformation projects integrating WMS/ERP/IoT ecosystems.

Why Choose Vinatech Group?

✅ World-class technology: Components from Siemens, Schneider, and top automation partners.
✅ Proven expertise: 10+ years in smart warehousing, serving Vinamilk, Nestlé, Unilever, Maersk, DHL and others.
✅ Custom engineering: Tailored 3D simulations, ROI calculations, and optimized warehouse layouts.
✅ Full turnkey solutions: Design → Equipment → Software → Installation → Training → After-sales support.
✅ Long-term reliability: 24/7 technical service, preventive maintenance, and uptime >98%.

Vinatech Group – Vietnam’s Leading Warehouse Storage Solution Provider

Head Offices:

• Hanoi: 15th Floor, TTC Building, 19 Duy Tan, Cau Giay, Hanoi
• Da Nang: 219–223 Pham Hung, Hoa Xuan, Cam Le, Da Nang
• Ho Chi Minh City: Lot C2-7, N7 Street, Tan Phu Trung Industrial Park, Cu Chi District