An automated stacking warehouse is a highly automated warehousing system. Below are some common fault analyses and handling methods:

I. Stacker Crane Malfunctions

1. Travel Malfunctions
- Malfunction Phenomenon: The stacker crane cannot travel normally along the track, and may experience jamming, track deviation, or complete inability to travel.
- Possible Causes:
- Obstacles or deformation on the track obstruct the normal operation of the stacker crane wheels. For example, goods scattered on the track or long-term heavy pressure on the track causing local deformation.
- Travel motor or reducer malfunction. Motor damage may be due to overload, long-term use aging, etc.; the reducer may have gear wear, insufficient lubricating oil, etc.
- Travel control system malfunction. For example, encoder damage, unable to accurately feedback the position information of the stacker crane, leading to deviation in travel control; or poor contact in the control circuit, signal transmission interruption.
- Handling Methods:
- Clean up debris on the track, repair or replace deformed tracks. For minor deformations, try to correct them with tools; if the deformation is severe, replace the track section.
- Check the motor and reducer. For the motor, the electrical parameters such as current and resistance can be checked to determine whether it is damaged, and if it is damaged, it should be replaced. For the reducer, check the oil quality and quantity of the lubricating oil, regularly replace the lubricating oil, and replace severely worn gears.
- For control system failures, first check the connection and status of the encoder, and replace it immediately if it is damaged. Check the wiring of the control circuit to ensure that the connection is firm, and tighten or replace poorly contacted components.

2. Lifting Malfunctions
- Malfunction Phenomenon: The stacker crane cannot lift normally, and may exhibit abnormal lifting speed, getting stuck in a certain position, or shaking during lifting.
- Possible Causes:
- Lifting chain or wire rope loosening or breakage. The chain or wire rope may wear out after long-term use, and is prone to breakage under heavy loads; or the chain or wire rope may loosen due to failure of the tensioning device.
- Lifting motor or reducer malfunction, the reason is similar to the travel motor.
- Lifting guide rail deformation or poor lubrication. Guide rail deformation will cause the stacker crane to experience additional resistance during lifting, and poor lubrication will increase the friction coefficient, resulting in unsmooth lifting.
- Sensor malfunction. For example, damage to the limit switch used to detect the position of the stacker crane may prevent the stacker crane from accurately stopping at the specified position.
- Handling Methods:
- Check and adjust the tension of the chain or wire rope. If the chain or wire rope shows signs of wear or breakage, replace it immediately.
- Check and repair the motor and reducer, the method is the same as the travel motor section.
- Check the straightness of the guide rail, and correct any deformed guide rails. At the same time, regularly lubricate the guide rails to ensure good lubrication.
- Check the working status of the sensor, replace the damaged sensor, and recalibrate the position and parameters of the sensor.

3. Fork Malfunctions
- Malfunction Phenomenon: The fork cannot extend or retract normally, the goods are not stably picked up, or the fork is deformed.
- Possible Causes:
- Fork motor or transmission mechanism malfunction. Motor damage or transmission gear wear, belt slack, etc., will cause abnormal fork movement.
- Damage to the fork's guiding device. For example, wear or loss of guide wheels will cause deviation of the fork during extension and retraction.
- Goods overload or improper placement, causing uneven force on the fork and deformation.
- Handling Methods:
- Check the fork motor and transmission mechanism. For the motor, check its electrical performance; for transmission gears and belts, check for wear and replace or adjust tension.
- Repair or replace the fork's guiding device to ensure that the fork can move smoothly and accurately during extension and retraction.
- Avoid overloading goods, and standardize operations when placing goods, and replace any deformed forks.

II. Conveyor System Malfunctions

1. Conveyor Malfunctions
- Malfunction Phenomenon: The conveyor cannot start, the running speed is abnormal, the conveyor belt deviates, or slippage occurs.
- Possible Causes:
- Motor malfunction, such as motor winding short circuit, open circuit, etc.
- Conveyor belt problems. After long-term use, the conveyor belt may stretch, wear, and tear, causing deviation or slippage.
- Roller or idler malfunction. Roller surface wear, bearing damage, or idler non-rotation will affect the normal operation of the conveyor belt.
- Control system malfunction, such as start button damage, incorrect controller parameter settings, etc.
- Handling Methods:
- Check the motor, judge whether the motor is damaged by measuring the resistance, insulation resistance, etc., and repair or replace it if it is damaged.
- For conveyor belt problems, if it is stretched, the tensioning device can be adjusted; for worn and damaged conveyor belts, repair or replace them according to the degree of damage.
Check the rollers and idlers. For rollers with surface wear, repair or replacement is possible; for rollers or idlers with bearing damage, replace the bearings; ensure that the idlers can rotate flexibly.
Check the control system, repair or replace damaged start buttons, and re-check and set controller parameters.

2. Sorting Equipment Malfunctions (if any)
Malfunction: The sorting equipment cannot correctly sort goods, sorting efficiency is low, or goods are stuck.
- Possible Causes:
Sensor malfunction. For example, damage to sensors used to identify the barcode or shape of goods, resulting in the inability to accurately obtain goods information for sorting.
Pneumatic or electric actuator malfunction. For example, pneumatic cylinder or solenoid valve malfunction, causing the sorting device to malfunction.
Sorting software problems. The software may have program errors, data loss, etc., affecting the sorting logic.
- Handling Methods:
Check the sensors, replace damaged sensors, and recalibrate the sensor position and parameters.
Check the pneumatic or electric actuators. For cylinders, check the piston, seals, and other components; for solenoid valves, check the power status and whether the air path is unobstructed. Repair or replace if necessary.
For software problems, check the software's running log to find the cause of the error. You can try reinstalling the software, restoring data backups, or contacting the software vendor for technical support.

III. Electrical System Malfunctions

1. Power Failure
Malfunction: The entire automated warehouse or part of the equipment suddenly loses power, or the voltage is unstable.
- Possible Causes:
Abnormal utility power supply, such as power outages or excessive voltage fluctuations.
Malfunction of the power distribution cabinet inside the automated warehouse. For example, circuit breaker tripping, contactor damage, or fuse blowing.
Cable failure. The cable may be bitten by mice, aged and damaged, or the connector may be loose, causing leakage or short circuit.
- Handling Methods:
Check the utility power supply, and communicate with the power supply department to confirm whether there is a power outage or voltage abnormality. If there is a voltage fluctuation problem, consider adding voltage stabilization equipment.
Check the power distribution cabinet. For tripped circuit breakers, identify the cause and then reclose them; for damaged contactors or fuses, replace them.
Check the cables. For cables bitten by mice, repair or replace them; for aged and damaged cables, replace them promptly; tighten the cable connectors to ensure good connection.

2. Control System Malfunctions
Malfunction: The equipment's control commands cannot be executed normally, the control system displays error messages, or communication is interrupted.
- Possible Causes:
PLC (Programmable Logic Controller) malfunction. This may be due to PLC program errors, CPU damage, or input/output module failure.
Communication network malfunction. For example, interruption or interference in communication lines such as industrial Ethernet or fieldbus.
Operating terminal malfunction. For example, touchscreen damage or malfunctioning operation buttons.
- Handling Methods:
For PLC malfunctions, first check if there are any errors in the PLC program. This can be done through online monitoring and checking program logs. If the CPU or input/output module is malfunctioning, replace or repair it as appropriate.
Check the communication network. Check the operating status of network devices (such as switches and routers), check whether the communication lines are unobstructed, and for interference, anti-interference measures such as shielding and grounding can be taken.
For operating terminal malfunctions, check the connection and display of the touchscreen. Replace it if damaged; for malfunctioning operation buttons, check the wiring and contacts of the buttons, and repair or replace them.

IV. Software System Malfunctions

1. Warehouse Management System (WMS) Malfunctions
Malfunction: Unable to perform normal warehousing and outbound operations, inaccurate inventory data, and chaotic task allocation.
- Possible Causes:
Database malfunction. For example, database file corruption, data loss, or hardware failure of the database server.
Problems with the WMS software itself. This may be due to compatibility issues after software updates, program vulnerabilities, or incorrect operation permission settings.
Network connection problems, causing data transmission between the WMS and the automated warehouse equipment to be interrupted.
- Handling Methods:
For database malfunctions, first check the hardware status of the database server, such as disk space and memory usage. If the database file is corrupted, try to restore the data using the backup file; for data loss, restore the data according to the backup strategy.
Check the WMS software version and update status. If it is a problem after a software update, try to roll back to the previous version or contact the software vendor to resolve compatibility issues. Check the operation permission settings to ensure that users have the correct operation permissions.
Check the network connection to ensure that the network communication between the WMS and the automated warehouse equipment is normal. This can be checked using network tools such as the ping command, and network failures can be repaired.