standard component library

Transcription

1 standard component library manual standard component library /21

2 standard component library manual 2/21 Table of Contents layouts Airport Baggage Handling High Volume Consumer Goods (HVCG) Packing Line 5 Pallet-based Electronics Assembly 6 Palletizing Line 7 Paper Conversion 8 Enterprise Logistics 9 Plant Simulation. 1 Job Shop 1 Standard Component Library 12 Manufacturing Components 1 Common Parameters1 Buffer1 Bundler1 Component Creator1 Component Sink1 Conveyor1 Conveyor Bend1 5 Conveyor Crossing X1 5 Conveyor Crossing Y1 5 Conveyor Merging X1 6 Conveyor Merging Y1 6 Conveyor Rotate1 6 Conveyor Vertical1 6 Dynamic Component (Part)1 7 Lifter1 7 Process Point1 7 Robot Palletizing1 7 Shuttle1 8 Wrapper1 8 Cartesian and Palletizing Robots1 8 Process Components 19 Process Component (order)1 9 Process Component Warehouse1 9 Process Order Creator1 9 Process Statistics 20 Process Workstation 20 Map of Finland

3 standard component library manual /21 airport BAGGage handling This solution simulates an airport Baggage Handling System where Passenger luggage is transferred from the check-in desks to the correct dispatch areas Creator components generate bags of different sizes, intervals, and colors. Three Conveyor_Merging_x components combine the component flow into a single conveyor. Vertical bends change the height level of the conveyor line. Five Conveyor_Crossing components divert the component flow to different output conveyors. Routing routing is based on the bag color, so that all the bags of one color will be diverted to the same output conveyor. Five outfeed conveyors bring the bags to their pick up point for loading to the trolleys at air-side. The Show Statistics tool can be used to check the baggage flow for each conveyor.

4 standard component library manual /21 High Volume consumer goods Line (HVCG) This layout exemplifies a typical high volume - high speed conveyor solution found in many food and dairy production applications Six ComponentCreator components feed components into the system with constant speed. Color is used to identify products from different infeeds. All components are combined into a single main conveyor using the Conveyor_Merging component. Based on product color the flow is diverted into two lines using the Conveyor_Crossing component. The Bundler collects incoming products into larger delivery units. The bundled goods flow on a single conveyor. A Shuttle is used to move components horizontally to the delivery area. The Wrapper component wraps the bundled goods with a plastic film.

5 standard component library manual 5/21 Packing LINE The Packing Line uses multiple product bundlers to collect goods into a final delivery package A ComponentCreator feeds product into the packing line. The Bundler component accumulates products into a bigger package. A Conveyor_rotate module is used to re-orient the products. An additional product accumulation stage. An a additonal product orientation stage. The Shuttle moves goods horizontally to another line. A Buffer is used to store items if the downstream route is blocked for any reason. A Single Conveyor_Crossing module delivers products evenly to one of three workstations. The workstations have an assigned process time to represent any type of process such as an inspection or manual operation. A Gantry robot stacks bundled product into a delivery sized stack.

6 standard component library manual 6/21 Pallet-based Electronics Assembly THIS Layout Demonstrates a pallet based electronics production assembly system. the Product product sits on a pallet throughout throughout the the assembly process and when finished the pallets return to the start of the system on a lower track New pallets are created with a single ComponentCreator component. The pallets are transferred onto the conveyor loop with a Conveyor_Merging component. In this layout the first workstation handles every second product and changes the product colour on completion of its task. Parts that have not yet been processed at the first workstation are identified by their color and diverted to the second workstation area for processing. The Workstation placed before the buffer (5) has been assigned time-to-failure mtbf MTBF and time- to-repair mttr values. The Buffer stores components if there is no room in the downstream workstation/conveyor. If if the workstation in front of the Buffer fails, the buffered products will feed into the line to avoid interrupting production for as long as possible. The Workstation after the buffer also has MTBF and MTTR values assigned. The Lower track and two end Lifters complete the pallet handling system.

7 standard component library manual 7/21 Palletizing line 1 2 Two in-feed conveyor lines with accumulators feed bundled products to a palletizing robot. The Bundles are placed on a Pallet which passes through a pallet wrapping machine Two ComponentCreators feed product onto the lines at constant intervals. Bundlers accumulate incoming products into larger packs. The Palletizing robot creates new pallet stacks. The Wrapper module completes the palletizing process.

8 standard component library manual 8/21 Paper conversion A High HiGH volume PAper paper tissue roll Packaging packaging line that that accumulates individual rolls into a large distribution pack Four ComponentCreator modules feed products into the line at a constant rate. Elevation sections move the product flow upwards. All tissue rolls are combined to a single highway with the Conveyor_Merging component. Rolls are manipulated and bundled several times in order to create the correct pack size for retail stores and consumer delivery. A tunnel section for vehicle and plant access (e.g. forklifts) is created by combining a elevated section with a lifter component. Bundles are packaged into delivery sized packs and wrapped with plastic film. A Sink component collects statistics at the end of the line.

9 standard component library manual 9/21 Enterprise Logistics 1 2 The Enterprise Logistics layout demonstrates A process/order flow through refineries, factories and 1 terminal Order Schedule and Reporting components generate the orders and collect information from the finished orders. The order starts in one of the refineries as defined by the first stage process in the order s route property. The order proceeds to the next factory as per its routing property. After completing all processing stages the order arrives at the distribution terminal (in Helsinki) where the results of the simulation can be viewed. The the red path an example route.

10 standard component library manual 10/21 Plant simulation 1 2 This layout represents schematically schematically several Production production and and packaging lines. The orders flow through the different lines depending on the routing stages defined in the order schedule Order Schedule and Reporting components generate the orders and collect information from the finished orders. The production starts when an order arrives at the beginning of the production line queue. Order s flow from one line to another until the route is complete. The red arrows is an example route.

11 standard component library manual 11/21 job shop The JOB shop queues product Batches at different Machine and process centers based on an order schedule with a defined routing for each batch The Order Schedule and Reporting components generate orders and collect information from the finished orders. The Process component warehouse contains information of available raw resources that will be needed for some process to start and also includes the replenishment times when outages ocurr. The Cutter module has an MTBF mtbf failure mode defined and also input material requirements that must be met before the process can start. The process will stop if there is a failure or shortage of input resources. The Drills are not defined with a failure mode or any resource requirements. The Lathe modules have MTBF mtbf failure modes defined as well as input material requirements that must be met before the process can start. The orange and red routes are example routes an order may take through the job shop. On completion of the simulation the statistics of the production run can be viewed using the reporting component(1)

12 standard component library manual 12/21 Standard Component Library The Standard Component Library is a set of highly-customizable simulation components that can be used to create a wide variety of production system layouts including all the example layouts in the preceeding chapter - without programming. They are intended for fast layout development and as a template for the development of new component models. Manufacturing Simulation Components Additonal manufacturing components: Process Simulation Components Additonal process simulation components:

13 standard component library manual 1/21 Manufacturing Components Common parameters Following are several parameters commonly found in the equiment library. Structure weight The structure weight is a geometrical feature that allows the material handling components to vary fro a light weight to a heavy construction. The following examples show the effect of varying the Structure Weight parameter for the values of 1, 1.5 and 2. Structure Weight = 1 Structure Weight = 1.5 Structure Weight = 2 Size and Speed The size of the component is defined in most cases by Length, Width and Height. The speed is a quantity, typically in mm/s. In the case of the Buffer and Bundler the size is also dependent on the quantity and size of the products in storage. Buffer The Buffer component is used to queue parts at a specific location. It contains several parameters and behaviours to fit with a large variety of applciations. The Buffer has two storage modes - First in, first out (FIFO) and Last in, first out (LIFO). The storage columns, rows and levels define the storage capacity of the buffer. The Buffer creates a matrix to store the incoming parts based on Product dimensions. Bundler The Bundler component is used to group product into a larger package for handling. The Bundler acts as a buffer for products until it s full. The capacity is defined by the Storage columns, rows and levels. When full the Bundler creates a new component equivalent in size to the bundled products and releases the new product bundle to the next operation.

14 standard component library manual 1/21 Component Creator The Component Creator dynamically loads part components into the DWorld. Several parameters control its behavior. The color is defined by the material list. The size is defined by the dimension parameters. The Interval defines the time taken before another part is created and the Creator Limit sets the total amount of parts generated. Component Sink The Component Sink is a component used to receive parts at the end of a simulation and is used for completing the information needed for statisitical reports. Typical data collected includes part and order throughput times. The product size defines the size of the Component component Sink. sink. Conveyor The Conveyor component is used for transportation. It is highly parametric, and can be configured to a variety of forms. All the example layouts in this manual use this conveyor component. The Length, Width and Height control the size of the conveyor component. The speed and capacity control the part flow through the conveyor. The most important visual parameters are the Conveyor Type, the Structure Weight, and the Amount of Feet. Below are some examples. Length = 2000 Legs = Radius = Length = 1000 Type = Roll Type = Belt Type = Chain Width = 1000 Weight = 1.5

15 standard component library manual 15/21 Conveyor Bend The Conveyor Bend has the same functionality as the straight conveyor. The amount of bend is defined with the parameters for Conveyor Angle and Conveyor Radius. Conveyor Angle values can range from 1 to 60. A left hand bend can be made by un-checking the TurnRight option. Bend = 5 Bend = 5 Turn Left Type = Belt Conveyor Crossing X The Conveyor Crossing X is used to divert or divide the flow of components into three lanes. The Radius of the bend cannot be directly controlled - it only provides a 90 bend. The Routing of the Conveyor Crossing is defined by the Route parameters. If the rules are defined as depicted in the parameter tab panel, the Conveyor Crossing will divert one product to each lane, starting from the center, then to the left and then to the right. If the rules are defined by Color, the same pattern will be followed. Conveyor Crossing Y The Conveyor Crossing Y is used to divert or divide the flow of components into two lanes. The Conveyor Crossing Y functions in the same way as the Crossing X. The bend can be defined with Turn Right checkbox.

16 standard component library manual 16/21 Conveyor Merging X The Conveyor Merging X is used to merge the flow of components from three lanes into one. The Route rules are automatic, and cannot be directly affected. If components are at all entry points, it will cycle through each input to infeed the parts. Conveyor Merging Y The Conveyor Merging Y is used to merge the flow of components from two lanes into one. The bend can be changed with the Turn Right check box. The Routing rules work the same way as with the Conveyor Merging X, taking a part from each input alternately. Conveyor Rotate The Conveyor Rotate component is used to orientate a single component or a bundle of components to suit the transportation mode. The Rotate function replaces the input component with a new output component in a new orientation. The Rotate paramater can be defined for all three axis ranging from -90, 90 and 180. It is recommended that you use the same size of the output component as the input. Conveyor Vertical The Conveyor Vertical is used to raise and drop the material flow level. The bend of the conveyor can be controlled with the Conveyor Angle, Radius and Turn Down checkbox. For a better visual effect use two conveyors in the form of an S-curve. Note that the Turn Down checkbox cannot be modified once the conveyor has been connected to another.

17 standard component library manual 17/21 Dynamic Component (Part) The Dynamic Component is the part loaded by the Component Creator into the D Environment. The parameters of this part are changed by all the other components, and there are no direct interaction parameters. Lifter The Lifter component has the capacity to receive and to feed components from distinct ports. Two of the ports are found at the bottom, and two at the top of the lift. The height of the lift is defined by the Lift Height, and this defines the position of the higher entry/exit ports. If a component arrives at any of these ports, the lifter will behave according to the rules set in the Route tab page. By default, it will first check the capacity of Port 1, then 2, and. It won t use ports that are not connected to a conveyor. Process Point The Process Point component is used to simulate any time taking part process. The processing point defines where the parts stop and for how long. The Process Point parameters behave the same way as a normal conveyor and the Size, Length, Width, Weight parameters can all be changed on the parameter tab page. The process capabilities are modified by the Function Parameters. Here you can modify the Process Time, which is the time a part stops at the Process Point. The Variation defines the random stoptime variation from part to part. MTBF (Mean Time Before Failure) defines the time the Process Point works without breaking down. MTTR (Mean Time To Repair) defines the time it will take for the Process Point to start working again. The Change Color and Product Color options control the part color after the operation is completed and this is used in decision logics of downstream processes. Robot Palletizing The Robot Palletizing component serves as the base for the two palletizing robots - the Palletizing Robot and the Cartesion Robot. It has handling logics for these robots, and generates the robot tasks on the fly based on inputs from the system. It contains three Input ports and one Output. The Output port behaves as a normal conveyor and buffer. The buffer size is defined by the Storage Columns, Rows and Levels. The Product Length, Width and Height define the final product or bundle size. The circular base represents the working area of the robot.

18 standard component library manual 18/21 Shuttle The Shuttle component is used to change the component flow from one lane to another. It behaves in the exactly same way as the Lifter component, except that the movement of the parts is horizontal. The Shuttle size is modified the same way as the conveyor. The only differences are the Track Length, which defines the distance the shuttle will travel and the Shuttle Speed, which defines the speed at which the shuttle will move. The Shuttle component has four ports, which can be either input or output, and will follow the routing rules defined in the Route tab page. Only ports with connections are used. Wrapper The Wrapper component is used to simulate a pallet wrapping station. The Wrapper makes three full rotations before releasing the component onwards. The time the rotations take is a function of the Process Time parameter. The size of the final component and the color are defined by the Product Length, Width, Height and Product Color. Cartesian and Palletizing Robot The Caterisan and Palletizing robots are full robot components with links, joints and kinematic structures. Both of these robots are commanded by the Robot Palletizing base, but they can be used by themselves in other tasks in connection with the robot teach page.

19 standard component library manual 19/21 Process Components Process Component (order) The Process Component or Order is a simple dynamic component used to represent orders in abstract process simulation layouts. It contains several parameters such as Product Count, Route, Order Start time, Deadline and Priority, as well as the order s time scale (Seconds, Hours, Days). This component and its parameters are not accessed directly, but are modified through the process simulation components. Process Component Warehouse The Process Component Warehouse holds stock materials required for different processes. In the warehouse you can define the capacity and the replenishment times for exhausted stocks to be replaced. By default, it stores ten different components, but more can be easily added using DCreate s Create page functionality. Process Order Creator The Process Order Creator defines the simulation layout s orders. It sets the Route, Priority, Volume and Deadline for the products. There are two ways of introducing orders. One is by modifying the parameters according to your needs, and then pressing Create Order. Then you can change parameters for a second order, and press Create Order once more. The list of orders is saved in the layout. This list can be accessed through the Orders tab page found in the parameters of the component. This list can be modified directly, following the same sequence of details as in the general parameter page.

20 standard component library manual 20/21 Process Statistics The Process Statistics component collects all process related statistics produced from a simulation run. Information is only gathered for components with the statistical behaviors that were added during the Create process. All the standard equipment components have this behaviour built-in The following Statistics window appears once you have pressed the Order Statistics button and it disappears automatically if you select any other program or window. Process Workstation Drill The Process Workstation component simulates invidual processing points or complete process steps in the production. Orders are moved automatically from one workstation to another based on defined routing and no connections are needed between components. Each workstation processes one order at a time while waiting in queue. After the process is complete, the order is moved to the next workstation, if the next workstation is busy it is queued. Orders with highest priority (lower Priorityvalue) are processed from the queue first. The Workstation s general statistics parameters can be accessed from Tools > Show Statistics. The Model parameter is used to change the appearance of the process workstation. It has five modes - Drill, Cutter, Lathe, Factory and Production Line. The Scale is used to define the time scale of the process. Cutter Lathe Factory Production Line

21 standard component library manual 21/21 The Process Name is used to define the route the orders will pass through the system. The route is defined in the Order Creator component. The Process Time is the cycle time for a single product. The total process time for the order is the Process Workstation s Process Time multiplied by the Order s Order Product Count paramter. The format is HH::MM::SS. The Buffer Capacity defines how many orders can be in the queue. MTBF (Mean Time Before Failure) defines how often the process stops for any reason such as an error, maintenance, material replenishment. This value in randomized at the start of the simulation and is repeated with a 10% random variation. MTTR (Mean Time To Repair) defines how long it will take for a process to resume production after a failure. Map of Finland An example component with the map of Finland. The only parameter that can be changed is the scale, which makes it bigger or smaller. It accepts integers as input.