Transforming Warehouse Logistics with VNL Autonomous Pallet Stackers

For many manufacturers, achieving full automation in internal logistics isn't just about optimizing individual processes. Often, it means a complete warehouse transformation—an upgrade that's no small feat. This process tests a supplier's technology, solution capabilities, and integration expertise.

This case study showcases how VisionNav Robotics, using an integrated system of autonomous forklifts and advanced logistics equipment, transformed a traditional transit warehouse into a high-efficiency, fully automated facility.

Project Overview

Our client, a global leader in commercial vehicle HVAC systems, operates advanced production and R&D centers worldwide, including in China, the US, Mexico, and Spain. With over 80% market share, their impact spans key regions globally.

The goal of this project was to automate one of the client's transit warehouses in East China, creating a fully automated process for managing inbound and outbound flows.

Project Background

Before the transformation, this warehouse served as a transit point for rapid in-and-out material handling. The space was mostly empty, with floor-stacked materials and inconsistent pallet sizes.

VisionNav introduced its proprietary RCS (Robot Control System), a warehouse management system, and multiple VNL20 autonomous pallet stackers. To complete the setup, VisionNav integrated beam racks, chain conveyors, lift transfer devices, depalletizers, weight detection tools, automated scanners, and other advanced equipment. Together, these changes transformed the warehouse from the ground up into a fully automated internal logistics hub.

To streamline pallet handling, VisionNav standardized on 1500 x 1500 mm pallets, simplifying inventory management and creating a more efficient operation.

Workflow Overview

Inbound Process:

• When the conveyor system detects an empty pallet stack, the RCS automatically initiates a replenishment task.
• The inbound conveyor system disassembles empty pallets and transports them to the loading area, where staff place materials on the pallets. They are then sent down the inbound conveyor line.
• Along the way, materials pass through weight checks, labeling, and wrapping stations. VisionNav's automated scanners can read barcodes through the wrapping, recording the material data and uploading it to the client's system, which syncs back with the RCS.
• When materials reach the end of the conveyor, the RCS dispatches a VNL20 forklift to retrieve them and place them onto racks.
• The racking system features four levels, and the VNL20 forklifts, equipped with custom masts, can lift up to 800 kg to heights over 5 meters, allowing efficient storage and retrieval from any level.

Outbound Process:

• The finished goods management system sends an outbound order to the warehouse management system and the RCS.
• The RCS generates an outbound task based on the order, directing a VNL20 forklift to retrieve materials from the specified rack and transfer them to the outbound area.

Empty Pallet Management:

• Once materials are shipped, empty pallets are sent back to a stacking area via conveyor, where they are stacked in sets of ten.
• The stacking system then sends a task to the RCS, which dispatches a VNL20 forklift to transport the stack to the pallet storage area.

Project Impact

This project was completed in just 30 days. With VisionNav's extensive experience and efficient implementation, the warehouse achieved an impressive automation upgrade, improving inbound and outbound efficiency, optimizing space utilization, and enabling smart, streamlined operations.

This project highlights VisionNav's expertise in delivering powerful automation solutions and integration capabilities. We're not just a technology provider—we're building smarter logistics. As a leader in the field, VisionNav aims to support more manufacturers in embracing the future of intelligent logistics .