Pepperl+Fuchs Enables Precise Shuttle Positioning in Automated Pallet Warehouses

Pepperl+Fuchs supplies the PCV DataMatrix positioning system for Eurofork’s E4SHUTTLE pallet shuttle. The solution enables absolute real-time positioning of shuttles and pallets in automated, multi-deep storage systems, supporting traceability, storage density and process reliability.

Real-Time Positioning for Pallet Shuttle Systems

Automated pallet shuttle warehouses require accurate position data at all times. Shuttles move autonomously through aisles and storage channels, placing and retrieving pallets in high-density storage systems. In multi-deep storage, where several pallets are stored behind one another in a channel, positioning accuracy becomes a critical factor for safe and efficient operation.

Eurofork, an Italian intralogistics solution provider based near Turin, uses Pepperl+Fuchs positioning technology in its E4SHUTTLE. The four-way pallet shuttle can move autonomously along the X and Z axes of the warehouse and change storage levels along the Y axis using a lifter.

This allows the shuttle to enter storage channels directly and reach individual pallet positions without additional equipment. For warehouse operators, this supports flexible storage layouts, high throughput and efficient use of available space.

PCV DataMatrix Positioning from Pepperl+Fuchs

The positioning task is handled by the PCV DataMatrix positioning system from Pepperl+Fuchs. PCV provides absolute positioning and enables detailed 3-D mapping of the warehouse. PCV read heads are mounted on the E4SHUTTLE and read DataMatrix code tapes installed throughout the warehouse.

The code tapes are placed in main aisles, storage channels and vertically along the lifts. Since the shuttle always knows its exact position, the position of each pallet can be determined automatically during storage and retrieval.

Compared with 1-D coding, DataMatrix coding offers significantly higher data capacity. The codes are redundant, allowing reliable reading even if the tape is bent, dirty or partly covered. This is essential in warehouse environments where dust, movement and mechanical stress can affect sensor and code surfaces.

Robust Reading in Complex Warehouse Layouts

The PCV read heads used in the shuttle application provide a reading window of 40 × 25 millimeters. This makes the system tolerant of lateral and vertical inclination, allowing reliable position detection even on gradients or uneven paths.

To meet Eurofork’s requirements, Pepperl+Fuchs developed a variant with a particularly large working range of over one hundred kilometers and high precision of 0.1 millimeters. This combination of range and accuracy is relevant for large automated warehouses where many shuttle movements must be coordinated precisely.

For system integrators and warehouse automation providers, the benefit lies in reliable absolute position data without depending on incremental referencing alone. The system supports precise machine movements and enables shuttles and pallets to remain traceable throughout the warehouse.

Traceability and Higher Storage Density

Absolute positioning improves both transparency and process security. Pallets and shuttles can be located precisely at any time, which supports complete traceability across storage and retrieval processes.

Precise positioning also enables smoother machine movements and more compact pallet storage. In multi-deep warehouses, this is particularly important because storage density directly affects capacity. Optimized pallet positioning can increase usable storage space without requiring structural expansion.

For end customers, Eurofork’s E4SHUTTLE with Pepperl+Fuchs positioning technology supports faster order management, better inventory control and more efficient warehouse operations.

Technology Partnership in Intralogistics

Eurofork has filed an international patent for the technology used for absolute, precise and reliable positioning behind the E4SHUTTLE and ESMARTSHUTTLE. The company describes Pepperl+Fuchs not only as a supplier, but as a technology partner contributing key components to its automated handling solutions.

For Pepperl+Fuchs, the application demonstrates how industrial positioning technology can support advanced intralogistics systems where flexibility, throughput and traceability must be combined in one automation architecture.

Planning automated pallet shuttle systems? Contact Pepperl+Fuchs to explore how PCV DataMatrix positioning can deliver real-time accuracy, full traceability and reliable warehouse automation.