Seamless Integration of VRCs into a BoxLogix-Driven AMR System

Challenge

Overview: 

In a complex, automated material-handling environment, OSCO Controls partnered with BoxLogix, AI Storage Solutions, Autoquip, and a leading end user to deliver a highly automated storage and retrieval solution leveraging Vertical Reciprocating Conveyors (VRCs) and Autonomous Mobile Robots (AMRs).

Within this collaborative ecosystem, Autoquip’s VRCs provided the vertical material movement backbone, while BoxLogix and AI Storage Solutions supplied the system-level automation and storage intelligence. OSCO served as the critical controls and integration partner—ensuring that all technologies operated together as one coordinated, safe, and reliable system.

OSCO’s role centered on translating high-level system commands into precise, dependable lift movements while maintaining clear system ownership, robust safety interlocks, and continuous state feedback across platforms.

The Challenge:

The customer’s material-handling system relied on Autoquip VRCs to move AMRs between levels under the direction of the BoxLogix software platform. Achieving this required tight coordination between mechanical lift equipment, mobile robotics, and centralized control logic.

Key challenges included:

• Enabling the upstream BoxLogix system to directly command Autoquip VRC movements to specific levels
• Coordinating all load and unload events between AMRs and Autoquip VRCs
• Ensuring safe transfer of AMRs on and off Autoquip’s lifting platforms
• Managing known risks such as signal loss while an AMR was positioned on a VRC
• Preventing premature lift motion or loss of position under fault conditions

Without a well-defined integration layer, these elements could behave as isolated subsystems—introducing safety risks, operational inefficiencies, and unreliable system behavior.

Solution

OSCO Controls developed and implemented the control logic that served as the integration layer between Autoquip’s VRC equipment, AMRs, and the higher-level BoxLogix and AI Storage Solutions software platforms. OSCO Controls developed and implemented the control logic that served as the integration layer between Autoquip’s VRC equipment and the higher-level BoxLogix software.

Key elements of the solution included:

Direct Interface with BoxLogix and Autoquip VRCs

OSCO’s control system interfaced directly with the BoxLogix architecture and Autoquip VRC controls, allowing system-level commands to initiate and manage lift movements to precise levels.

Clear Handshaking and System Ownership

Defined handshaking protocols established clear ownership of commands and states between BoxLogix, OSCO’s control logic, and the Autoquip VRCs—eliminating ambiguity and ensuring predictable operation.

Safe AMR Transfer on Autoquip Platforms

OSCO engineered logic to manage the safe transition of AMRs on and off Autoquip VRC platforms, including shot pin actuation to positively restrain the AMR until all safety and position conditions were verified.

Robust Interlocks and Fault Handling

To address known challenges such as signal loss while AMRs were on the Autoquip VRCs, OSCO incorporated robust interlocks and fault-handling routines. These safeguards prevented unintended lift movement, maintained positional integrity, and ensured the system defaulted to a safe state under abnormal conditions.

Reliable State Feedback from Autoquip VRCs

Continuous, accurate feedback from the Autoquip VRCs to the BoxLogix system ensured that all downstream decisions were based on verified, real-time equipment states.

Result

By translating system-level commands into safe, coordinated lift motion on Autoquip VRCs, OSCO Controls enabled the entire material-handling solution to function as a single, integrated system rather than a collection of independent subsystems.

The result was:

• Seamless coordination between AMRs, Autoquip VRCs, and BoxLogix
• Improved system safety through positive restraint and verified conditions
• Increased reliability despite communication or signal challenges
• Predictable, repeatable Autoquip VRC operations aligned with upstream system logic