Application solution
Logistics Industry — Shuttle & Conveyor
Warehouse automation system integrators and 3PL operators deploying 4-way pallet shuttles, tank shuttles, air shuttles, spider vehicles, climbing robots, and servo conveyor lines.
Servo motion stack for warehouse and logistics automation. Specialized positioning algorithm achieves <em>±2mm travel accuracy</em> at 4 m/s with ±1mm fork extension precision. <em>MTPA motor control strategy</em> delivers up to <em>51% power savings</em> vs traditional AC asynchronous motor schemes. Pre-validated BOM recipes for Tank Shuttle (50kg), 4-Way Pallet Shuttle (1.5T), Air Shuttle, and Spider Vehicle.
The application demands · what we engineer
Tank Shuttle (50kg)
- Max travel speed 4 m/s, max acceleration 2 m/s²
- Travel positioning ±2mm, fork extension ±1mm
- 5-axis integrated servo configuration
4-Way Pallet Shuttle (1.5T)
- Speed 2 m/s, acceleration 0.5 m/s²
- 80-flange 1.5kW high-power motor reduces chassis height to standard pallet
- Specialized positioning algorithm for smoother operation
Conveyor & Fork Servos
- Pallet conveying: 70mm diameter, 600rpm (14 m/min), 60Nm torque, 1T payload
- Tank fork toggle servo: 24V Modbus, 60rpm no-load, 0.16Nm rated
- Servo + non-powered roller solution for sortation
System architecture
Controller → LOGISTICS components over a shared control / motion bus. Derived from the recommended BOM.
Architecture as text
- TANK-SHUTTLE: iSMD80-100-DQAK-AAK-000 — 50kg shuttle travel · 750W
- TANK-SHUTTLE: iSMD80-040-DQAK-AAK-000 — 50kg shuttle traverse / widening · 400W
- TANK-SHUTTLE: iSMD60-040-DQAK-AAK-000 — 50kg shuttle fork extension · 400W
- TANK-SHUTTLE: iSMD80-075-DQAK-AAK-000 — 50kg shuttle direction change · 750W
- 4-WAY-1.5T: SMC80S-0150-30AAK-5DSUFD145-AB-000 — 1.5T travel · 80-flange 1.5kW
- 4-WAY-1.5T: SMC80S-0120-30SBK-5DSUFD145-AB-000 — 1.5T jacking · with brake
- AIR-SHUTTLE: iSMD80-075-DQBK-CAK-000 × 4 — Air shuttle 30kg travel · 750W with brake
- AIR-SHUTTLE: iSMD80-100-DQBK-CAK-000 × 2 — Air shuttle lifting · 1KW with brake
- SPIDER: iSMD60-040-DQBK-EAK-000 × 4 — Spider vehicle travel · 400W
- SPIDER: iSMD80-075-DQBK-EAK-000 × 4 — Spider vehicle winches · 750W
- CONVEYOR: iSMK60-021-DMAK-AA-000-BSC × 2 — Conveying + jacking · 50kg pallet
- FORK-SERVO: Tank Fork Toggle Servo — 24V · Modbus · 0.16/0.48Nm · 52×28×66mm
- CTRL: Kinco AK840 — EtherCAT master · anti-shaking algorithm
Bill of materials
The engineered stack — components appear here as evidence. Each links to its product family.
| Role | Component | Key spec |
|---|---|---|
| TANK-SHUTTLE | iSMD80-100-DQAK-AAK-000 | 50kg shuttle travel · 750W |
| TANK-SHUTTLE | iSMD80-040-DQAK-AAK-000 | 50kg shuttle traverse / widening · 400W |
| TANK-SHUTTLE | iSMD60-040-DQAK-AAK-000 | 50kg shuttle fork extension · 400W |
| TANK-SHUTTLE | iSMD80-075-DQAK-AAK-000 | 50kg shuttle direction change · 750W |
| 4-WAY-1.5T | SMC80S-0150-30AAK-5DSUFD145-AB-000 | 1.5T travel · 80-flange 1.5kW |
| 4-WAY-1.5T | SMC80S-0120-30SBK-5DSUFD145-AB-000 | 1.5T jacking · with brake |
| AIR-SHUTTLE | iSMD80-075-DQBK-CAK-000 × 4 | Air shuttle 30kg travel · 750W with brake |
| AIR-SHUTTLE | iSMD80-100-DQBK-CAK-000 × 2 | Air shuttle lifting · 1KW with brake |
| SPIDER | iSMD60-040-DQBK-EAK-000 × 4 | Spider vehicle travel · 400W |
| SPIDER | iSMD80-075-DQBK-EAK-000 × 4 | Spider vehicle winches · 750W |
| CONVEYOR | iSMK60-021-DMAK-AA-000-BSC × 2 | Conveying + jacking · 50kg pallet |
| FORK-SERVO | Tank Fork Toggle Servo | 24V · Modbus · 0.16/0.48Nm · 52×28×66mm |
| CTRL | Kinco AK840 | EtherCAT master · anti-shaking algorithm |
Candidate BOM, subject to engineering review. Kinco performance and installed-base figures reflect the manufacturer's product portfolio. Trademarks belong to their respective owners.
What we engineered & validated
Payload class drives motor frame: 50kg → iSMD80, 1.5T → SMC80S 80-flange 1.5kW.
Anti-shaking PLC algorithm required for spider cars to prevent load table oscillation during short-distance handling.
Integrated servos consolidate motor + encoder + drive cabling, reducing field wiring by ~60% vs split designs
AC asynchronous + VFD shuttle replacement: motor frame and gearbox typically differ — mechanical re-validation required.
Related
Frequently asked
What energy savings can the MTPA control strategy actually deliver?
Kinco's published material states up to 51% power savings vs traditional AC asynchronous motor schemes (source: Kinco 2026 Logistics Industry Profile V1.1 EN). Actual savings depend on duty cycle, payload variation, and the baseline motor type being replaced.
Can your shuttle BOMs adapt to non-standard pallet sizes?
The published BOM is sized for standard EU/JP pallet platforms. Non-standard pallet sizes (1.2×1.2m, 1.5×1.5m heavy) require engineering review of motor torque, gearbox ratio, and chassis stress.
Do these solutions support being controlled by a 3rd-party WMS?
Yes via standard Modbus TCP, EtherCAT, or CANopen interfaces. WMS integration depth (recipe push, real-time status, exception handling) depends on the WMS vendor's API and integration effort.
What we are
An independent engineering & sourcing partner. We architect the logistics stack, select and integrate the BOM across supplier lines, and validate the system before you commit.
Where it does not fit
Ultra-heavy shuttle applications above 2T per vehicle (consult engineering) Component certifications are per datasheet; system-level certification of your finished machine remains the integrator's responsibility, subject to engineering review.
How this solution is delivered
You describe the application, program or BOM; we confirm what the service covers — and what it does not.
An engineer reviews materials against our supplied lines and flags risks and limits.
You receive a scoped work plan with deliverables and boundaries — before any commitment.
Work is delivered against the agreed scope, with documentation and hand-off.
Related engineering services
These services define the review boundary around this reference architecture. Candidate selections remain subject to engineering review.
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Have us review this solution for your platform
Send your application and requirements. We will scope a candidate BOM, the required validation and an availability check before quotation.