Distributed Control Nodes for Material Flow System Controls on the Example of Unit Load Conveyor and Sorter Facilities

The Chair of Transportation and Ware-housing at the University of Dortmund together with its industrial partner has developed and implemented a decentralized control system based on embedded technology and Internet standards. This innovative, highly flexible system uses autonomous software modules to control the flow of unit loads in real-time. The system is integrated into Chair’s test facility consisting of a wide range of conveying and sorting equipment. It is built for proof of concept purposes and will be used for further research in the fields of decentralized automation and embedded controls. This presentation describes the implementation of this decentralized control system.

Control concept for autonomous changeable material flow systems

Today’s material flow systems for mass customization or dynamic productions are usually realized with manual transportation systems. However new concepts in the domain of material flow and device control like function-oriented modularization and intelligent multi-agent-systems offer the possibility to employ changeable and automated material flow systems in dynamic production structures. These systems need the ability to react on unplanned and unexpected events autonomously.

Simulative study of the decentralized control of complex conveyor networks

Decentralised controls offer advantages for the implementation as well as the operation of controls of steady conveyors. Such concepts are mainly based on RFID. Due to the reduced expense for appliances and software, however, the plant behaviour cannot be determined as accurately as in centrally controlled systems. This article describes a simulation-based method by which the performances of these two control concepts can easily be evaluated in order to determine the suitability of the decentralised concept.

Performance Evaluation of Material Flow Systems in Discrete Time

Im folgenden Beitrag werden zeitdiskrete analytische Methoden vorgestellt, mit Hilfe derer Informations- und Materialflüsse in logistischen Systemen analysiert und bewertet werden können. Bestehende zeitdiskrete Verfahren sind jedoch auf die Bearbeitung und Weitergabe in immer gleichen Mengen („One Piece Flow“) beschränkt. Vor allem in Materialflusssystemen kommt es, bedingt durch die Zusammenfassung von Aufträgen, durch Transporte und durch Sortiervorgänge, zur Bildung von Batches. Daher wurden analytische Methoden entwickelt, die es ermöglichen, verschiedene Sammelprozesse, Batchankünfte an Ressourcen, Batchbearbeitung und Sortieren von Batches analytisch abzubilden und Leistungskenngrößen zu deren Bewertung zu bestimmen. Die im Rahmen der Entwicklungsarbeiten entstandene Software-Lösung „Logistic Analyzer“ ermöglicht eine einfache Modellierung und Analyse von praktischen Problemen. Der Beitrag schließt mit einem numerischen Beispiel.

Technical throughput of material flow systems required to achieve design flow – determined by simulation with aniteration algorithm

This article deals with complex material flow systems and series connections of conveyor and op-erating elements. These can be characterised by a specific availability. The thus resultant overall availabil-ity of necessary “technical throughput” of the individual elements for the achievement of a specified throughput. When the conveyor and operating elements are subjected to a stochastic distribution, the interposition of buffers is necessary but these can also lead to a reduction of the necessary throughput due faults. The system behaviour of complex installations can only be investigated by simulation. The parame-ter changes required in order to achieve specific target values can also be determined by simulation runs in iteration loops.

Development of a novel material flow simulation model for the integration of spatial and process relevant information

Simulation techniques are almost indispensable in the analysis of complex systems. Materials- and related information flow processes in logistics often possess such complexity. Further problem arise as the processes change over time and pose a Big Data problem as well. To cope with these issues adaptive simulations are more and more frequently used. This paper presents a few relevant advanced simulation models and intro-duces a novel model structure, which unifies modelling of geometrical relations and time processes. This way the process structure and their geometric relations can be handled in a well understandable and transparent way. Capabilities and applicability of the model is also presented via a demonstrational example.

Simulative Untersuchung dezentraler Steuerungsverfahren komplexer Fördernetze

Dezentrale Steuerungstechnologien lassen Vorteile sowohl für die Implementierung als auch den späteren Betrieb des Steuerungsverbundes von Stetigfördersystemen erwarten. Gestützt werden solche Konzepte wesentlich durch die RFID-Technologie. Der verringerte Aufwand für Gerätetechnik und Softwarerealisierung bedeutet aber auch, dass das Anlagenverhalten nicht mehr - wie in zentral gesteuerten Systemen - vollständig determiniert ist. In diesem Artikel wird ein simulationsbasiertes Verfahren vorgestellt, mit dem strategieinduzierte Leistungsunterschiede dieser beiden Steuerungskonzepte vereinfachend, aber umfassend untersucht werden können, um die Eignung des dezentralen Konzeptes zu überprüfen.

Kollaborative Planung dezentral gesteuerter Materialflusssysteme in der Intralogistik

Der Beitrag stellt eine Kollaborationssoftware vor, die im Rahmen des AiF-Forschungsprojektes „KoDeMat“ entwickelt wurde. Der Fokus wird auf die Problemfelder der fehlenden Standardisierung und Anpassbarkeit im Bereich von fördertechnischen Anlagen gerichtet. Ziel ist, unter Zuhilfenahme von standardisierten, kollaborativen Engineeringprozessen, eine unternehmensübergreifende Planung, Realisierung und einen Umbau von komplexen dezentral gesteuerten Intralogistiksystemen sowie deren Betrieb effizient zu ermöglichen.

RFID Transponders : Link between information and material flows. How reliable are identification procedures?

Along with the growing complexity of logistic chains the demand for transparency of informations has increased. The use of intelligent RFID-Technology offers the possibility to optimize and control all capacities in use, since it enables the identification and tracking of goods alongside the entire supply chain. Every single product can be located at any given time and a multitude of current and historical data can be transferred. The interaction of the flow of material and the flow of information between the various process steps can be optimized by using RFID-Technology since it guarantees that all required data is available at the right time and at the right place. The local accessibility and convertibility of data allows a flexible, decentralised control of logistic systems. As additional advantages of RFID-Components can be considered that they are individually writable and that their identification can be achieved over considerable distances even if there is no intervisibility between tag and reader. The use of RFID-Transponder opens up new potentials regarding process security, reduction of logistic costs or availability of products. These advantages depend on reliability of the identification processes. The undisputed potentials that are made accessible by the use of RFID-Elements can only be beneficial when the informations that are decentralised and attached to goods and loading equipment can be reliably retrieved at the required points. The communication between tag and reader can be influenced by different materials such as metal, that can disturbed or complicate the radio contact. The communications reliability is subject of various tests and experiments that analyse the effects of different filling materials as well as different alignments of tags on the loading equipment.

Dynamic merge of discrete goods flow – Impact on throughput and efficiency

Continuous conveyors with a dynamic merge were developed with adaptable control equipment to differentiate these merges from competing Stop-and-Go merges. With a dynamic merge, the partial flows are manipulated by influencing speeds so that transport units need not stop for the merge. This leads to a more uniform flow of materials, which is qualitatively observable and verifiable in long-term measurements. And although this type of merge is visually mesmerizing, does it lead to advantages from the view of material flow technology? Our study with real data indicates that a dynamic merge shows a 24% increase in performance, but only for symmetric or nearly symmetric flows. This performance advantage decreases as the flows become less symmetric, approaching the throughput of traditional Stop-and-Go merges. And with a cost premium for a continuous merge of approximately 10% due to the additional technical components (belt conveyor, adjustable drive engines, software, etc.), this restricts their economical use.

Unterstützung des Managements von großen Netzen in der Logistik durch die systematische Bereitstellung von Methodenwissen

Das Management komplexer, interorganisatorischer und durch eine Vielzahl unterschiedlicher Beziehungen miteinander verknüpfter Strukturen und Prozesse, wie sie großen Netzen der Logistik zu-grunde liegen, stellt für die verantwortlichen Akteure eine anspruchsvolle Aufgabe dar. Der nachfolgende Beitrag stellt einen systematischen Ansatz vor, mit dem Netzwerkmanager bei der Erfüllung dieser Auf-gabe durch eine verbesserte Informationsgrundlage über verfügbare Methoden und Gestaltungsoptionen unterstützt werden sollen. Exemplarisch demonstriert wird die Funktionsweise dieses Ansatzes anhand des umfangreichen Instrumentariums des Netzwerk-Controlling, welches zur Schaffung von Transparenz in den unternehmensübergreifenden Prozessen zur Verfügung steht.

Utilizing the full Capacity of Sorting Systems with new Infeed Technology

Utilisation of sorting systems’ maximum performance demands continuous conveying of goods by infeed lines to sorters. This is the case especially for sorters with one single infeed line, because the sorters’ performance is limited by the performance of the infeed line. Within this paper different infeed line constructions at the Rotary Sorter with diverse performances will be presented. The focus lies on a specific conveying system to synchronise the goods with the sorter by a performance of 6000 pieces per hour with one dynamic infeed line. By this means there is no extensive adjustment control of serial conveyors in the infeed line any longer.

Lagerverwaltung und Bestandsmanagement in dezentral gesteuerten Systemen

Die Verwaltung von Lagerbeständen in Unternehmen muss erhebliche Anforderungen an die Datenverfügbarkeit, -sicherheit und -konsistenz erfüllen. Dies wird heute durch eine zentrale Datenhaltung in Lagerverwaltungssystemen gewährleistet. Auf der anderen Seite ist in vielen Bereichen (z. B. Materialfluss- und Transportsteuerung, Produktionssteuerung) eine Entwicklungstendenz in Richtung dezentraler Steuerungsstrategien zu beobachten, welche eine erhöhte Flexibilität und reduzierte Komplexität versprechen. Im Rahmen eines von der Deutschen Forschungsgemeinschaft (DFG) geförderten Projekts werden im vorliegenden Beitrag Konzepte zur verteilten Gestaltung von Lagerverwaltungssystemen vorgestellt und diskutiert.