IIoT Based Efficiency Optimization in Logistics Applications

The Industrial Internet of Thing (IIoT) approach to an Industry plant design, devises a comprehensive interconnection of the system components, from sections up to single devices, in order to get a general and punctual understanding of the process. Such an intelligent network, mostly based on Ethernet basic layers, when properly conceived, should be able to add relevant value to the plant operation. This paper shows how, within the IIoT frame topics, the plant efficiency can be addressed and bring relevant improvement. The reason is that variables directly related to the energy consumption, such as current, electric power, actuator and motor torque, speed, etc., can be timely and easily monitored in the entire plant, since they are already conveyed on the network, due to real time control and diagnostics purpose. A power consumption diagram can be derived, and give hints on how to optimize operations, based on some efficiency index. The paper, after a general discussion, proves it with practical examples based on a Gantry robot, driven in an EtherCAT based automation network, and on the stacker cranes of an automated warehouse

Dynamic Modelling of an Automated Vehicle Storage and Retrieval System and a Simulation Analysis of its Efficiency

In this paper operating-time models for single and multiple instructions are set up considering an AVS/RS (automated vehicle storage and retrieval system). The operation times of AVS/RS and AS/RS (automated storage and retrieval system) are simulated in different situations by changing the shelf structure and order density. The results show that the AVS/RS is more efficient than the AS/RS in all situations. Furthermore, the numbers of rows and columns of storage shelves greatly influence the operation time. The graph of operation-time compression ratio against number of columns shows an inverted U-type distribution, and the compression ratio decreases and ultimately tends to zero as the number of rows is increased. Also, the order density affects the efficiency difference between the two systems: the higher the order density, the higher the AVS/RS operating-time compression rate. Finally, compared with the AS/RS, the AVS/RS operating-time compression ratio improves greatly with increasing density and number of rows because of parallel operations, whereas with decreasing density and number of rows the AVS/RS advantages are gradually lost and the compression ratio decreases and eventually even reaches zero

Analysis and full automation of an industrial system: functional optimization and vertical integration

This final project describes the entire automation procedure for a power & free conveyor and a double level conveyor belt. After a detailed description of both systems under mechanical and electrical perspectives, the thesis explains the implementation of an operating mode that complies with safety rules and ensures power saving as much as possible. Complete but intuitive HMI are realized; in addition, according to vertical integration, alarm diagnostic and database management are provide

Compositional optimization of large-scale discrete event systems

Optimization of industrial processes such as manufacturing cells can have great impact on their performance. Finding optimal solutions to these large-scale systems is, however, a complex problem. They typically include multiple subsystems, and the search space generally grows exponentially with each subsystem. This is usually referred to as the state explosion problem and is a well-known problem within the control and optimization of automation systems.This thesis proposes a new method of solving these optimization problems using a compositional optimization approach. This integrates optimization with techniques from compositional supervisory control, dividing the optimization of subsystems into separate sub-problems. The key to this approach is the identification of local behavior in subsystems, behavior that is independent of all other subsystems. It is proven in this thesis that this local behavior can be optimized individually without affecting the global optimal solution. This is used by the approach, to reduce the state space in each subsystem, and then to utilize these reduced models compositionally when the global optimal solution is computed.Results in this thesis show that compositional optimization efficiently can generate global optimal solutions to large-scale optimization problems, too big to solve based on traditional monolithic models. It is also shown that these techniques can be applied to several industrial applications, e.g. in logistics, manufacturing etc

Past, state-of-the-art and future of intralogistics in relation to megatrends

Nakon kratkog pregleda istorije intralogistike, ovaj rad izučava pogled na navedene tehnologije. One su u vezi sa t.z.v. 'megatrendovima' kao što su globalizacija, urbanizacija, demografske i klimatske promene, za koje se očekuje da donesu globalne promene u nekoliko sledećih decenija i koje će najverovatnije odrediti buduću ulogu intralogistike i fokus istraživanja u ovoj oblasti.After briefly reviewing the history of intralogistics, this paper examines the outlook for the technologies concerned. This is related to the so-called 'megatrends', such as globalisation, urbanisation, demographic shifts and climate change, which are expected to bring about major global transformations over the next few decades, and which are also likely to determine the future functions of intralogistics and the focus of research in the field

Modelling flexible manufacturing systems through discrete event simulation

As customisation and product diversification are becoming standard, industry is looking for strategies to become more adaptable in responding to customer’s needs. Flexible manufacturing systems (FMS) provide a unique capability where there is a need to provide efficiency through production flexibility. Full potential of FMS development is difficult to achieve due to the variability of components within this complex manufacturing system. It has been recognised that there is a requirement for decision support tools to address different aspects of FMS development. Discrete event simulation (DES) is the most common tool used in manufacturing sector for solving complex problems. Through systematic literature review, the need for a conceptual framework for decision support in FMS using DES has been identified. Within this thesis, the conceptual framework (CF) for decision support for FMS using DES has been proposed. The CF is designed based on decision-making areas identified for FMS development in literature and through industry stakeholder feedback: set-up, flexibility and schedule configuration. The CF has been validated through four industrial simulation case studies developed as a part of implementation of a new FMS plant in automotive sector. The research focuses on: (1) a method for primary data collection for simulation validated through a case study of material handling robot behaviour in FMS; (2) an approach for evaluation of optimal production set-up for industrial FMS with DES; (3) a DES based approach for testing FMS flexibility levels; (4) an approach for testing scheduling in FMS with the use of DES. The study has supported the development of systematic approach for decision making in FMS development using DES. The approach provided tools for evidence based decision making in FMS

Past, state-of-the-art and future of intralogistics in relation to megatrends

Nakon kratkog pregleda istorije intralogistike, ovaj rad izučava pogled na navedene tehnologije. One su u vezi sa t.z.v. 'megatrendovima' kao što su globalizacija, urbanizacija, demografske i klimatske promene, za koje se očekuje da donesu globalne promene u nekoliko sledećih decenija i koje će najverovatnije odrediti buduću ulogu intralogistike i fokus istraživanja u ovoj oblasti.After briefly reviewing the history of intralogistics, this paper examines the outlook for the technologies concerned. This is related to the so-called 'megatrends', such as globalisation, urbanisation, demographic shifts and climate change, which are expected to bring about major global transformations over the next few decades, and which are also likely to determine the future functions of intralogistics and the focus of research in the field

A study of alternative forms of flexible manufacturing systems

The study relates to manufacturing conditions in a particular company. Flow synthesis and cell formation analysis have been conducted. A modification of methodology proposed by other researchers has assisted analysis. The main investigation is concerned with modelling, simulation and evaluation of seven alternative FMS configurations conceived for the machining cell manufacturing prismatic parts. The alternative systems encompass 6 CNC machines with (i) manual transport of materials and tools, (ii) with two and four station automated pallet changers, (iii) conveyor system, (iv) stacker crane, (v) rail guided shuttle, and (vi) AGV transport. [Continues.