Simulation and analysis of an emergency lowering system for crane applications

An emergency lowering system for use in safety critical crane applications is discussed. The system is used to safely lower the payload of a crane in case of an electric blackout. The system is based on a backup power source, which is used to operate the crane while the regular supply is not available. The system enables both horizontal and vertical movements of the crane. Two different configurations for building the system are described, one with an uninterruptible power source (UPS) or a diesel generator connected in parallel to the crane’s power supply and one with a customized energy storage connected to the intermediate DC-link in the crane. In order to be able to size the backup power source, the power required during emergency lowering needs to be understood. A simulation model is used to study and optimize the power used during emergency lowering. The simulation model and optimizations are verified in a test hoist. Simulation results are presented with non-optimized and optimized controls for two example applications: a paper roll crane and a steel mill ladle crane. The optimizations are found to significantly reduce the required power for the crane movements during emergency lowering.

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.

Fuzzy Multi-Objective Linear Programming and Simulation Approach to the Development of Valid and Realistic Master Production Schedule

Master production schedule (MPS) plays an important role in an integrated production planning system. It converts the strategic planning defined in a production plan into the tactical operation execution. The MPS is also known as a tool for top management to control over manufacture resources and becomes input of the downstream planning levels such as material requirement planning (MRP) and capacity requirement planning (CRP). Hence, inappropriate decision on the MPS development may lead to infeasible execution, which ultimately causes poor delivery performance. One must ensure that the proposed MPS is valid and realistic for implementation before it is released to real manufacturing system. In practice, where production environment is stochastic in nature, the development of MPS is no longer simple task. The varying processing time, random event such as machine failure is just some of the underlying causes of uncertainty that may be hardly addressed at planning stage so that in the end the valid and realistic MPS is tough to be realized. The MPS creation problem becomes even more sophisticated as decision makers try to consider multi-objectives; minimizing inventory, maximizing customer satisfaction, and maximizing resource utilization. This study attempts to propose a methodology for MPS creation which is able to deal with those obstacles. This approach takes into account uncertainty and makes trade off among conflicting multi-objectives at the same time. It incorporates fuzzy multi-objective linear programming (FMOLP) and discrete event simulation (DES) for MPS development.

Simulation der peristaltischen Förderung von Stückgütern als Schüttgut

Im Beitrag wird ein neuartiges Förderprinzip zur federnden Aufnahme und zum Transport von massenhaft anfallenden Paketstrukturen vorgestellt. Das Förderprinzip beruht auf einem flächigen Tragmittel in Form eines veränderbaren, elastischen Verbundes von kleinskaligen Fördermodulen. Das konzipierte Transportprinzip mit peristaltischen Eigenschaften soll entstehende Staus der Pakete schnell auflösen und eine dedizierte Steuerung von Teilmengen zulassen, um den erforderlichen Durchsatz innerhalb eines Materialflusssystems zu erreichen. Diese Lösung ermöglicht eine sinnvolle Verknüpfung von Wirkprinzipien der Schüttgut- und Stückgutförderung zur Aufnahme und Fortbewegung von Pakete als Schüttgut. Die Grundfunktionalität des Förderkonzepts wird durch die numerische Simulation auf Basis der Diskrete Elemente Methode sowie der Mehrkörpersimulation überprüft.

Design, Simulation und Erprobung einer aktiven Sitzaufhängung für Nutzfahrzeuge

Nutzfahrzeuge müssen oft durch sehr unebenes Gelände gefahren werden. In diesem Fall wird der Fahrer starken Vibrationen ausgesetzt, die von der Fahrzeugkarosserie durch die Sitzaufhängung auf ihn wirken. Um diese Schwingungen zu verringern, werden die Sitzaufhängungen in der Regel mit Feder-Dämpfer-Systemen ausgerüstet. Jedoch erreichen die passiven Systeme vor allem bei niederfrequenten Schwingungen ihre physikalischen Grenzen. Eine wesentliche Verbesserung des Sitzkomforts kann unter solchen Anregungsbedingungen nur mit einer aktiven Sitzaufhängung erreicht werden. In diesem Beitrag wird ein neuartiges aktives System für die Sitzaufhängung auf Basis von elektrorheologischen Flüssigkeiten vorgestellt. Außerdem werden die theoretischen Grundlagen für die Modellierung der beschriebenen aktiven Sitzaufhängung dargestellt. Anschließend werden die Simulationsergebnisse mit den Messergebnissen unter realen Betriebsbedingungen verglichen. Die Repräsentation der Ergebnisse mit Hilfe der im Bereich der Sitztechnik weit verbreiteten SEAT-Werten (Seat Effective Amplitude Transmissibility) zeigt das Potenzial des entwickelten Systems zur aktiven Reduktion der Schwingungsbelastung des Fahrers und ermöglicht seine objektive Bewertung.

Performance Availability and Anticipatory Change Planning of Intralogistics Systems: A Simulation-Based Approach

In recent years, the ability to respond to real time changes in operations and reconfigurability in equipment are likely to become essential characteristics for next generation intralogistics systems as well as the level of automation, cost effectiveness and maximum throughput. In order to cope with turbulences and the increasing level of dynamic conditions, future intralogistics systems have to feature short reaction times, high flexibility in processes and the ability to adapt to frequent changes. The increasing autonomy and complexity in processes of today’s intralogistics systems requires new and innovative management approaches, which allow a fast response to (un)anticipated events and adaptation to changing environment in order to reduce the negative consequences of these events. The ability of a system to respond effectively a disruption depends more on the decisions taken before the event than those taken during or after. In this context, anticipatory change planning can be a usable approach for managers to make contingency plans for intralogistics systems to deal with the rapidly changing marketplace. This paper proposes a simulation-based decision making framework for the anticipatory change planning of intralogistics systems. This approach includes the quantitative assessments based on the simulation in defined scenarios as well as the analysis of performance availability that combines the flexibility corridors of different performance dimensions. The implementation of the approach is illustrated on a new intralogistics technology called the Cellular Transport System.