Tecnomatix Plant Simulation

Transcription

1 Tecnomatix Plant Simulation

2 Steffen Bangsow Tecnomatix Plant Simulation Modeling and Programming by Means of Examples ABC

3 Steffen Bangsow Freiligrathstrasse Zwickau Germany Translated by Steffen Bangsow ISBN ISBN (ebook) DOI / Library of Congress Control Number: Springer Cham Heidelberg New York Dordrecht London c Springer International Publishing Switzerland 2015 Translation from the German language edition: Praxishandbuch Plant Simulation and Simtalk by Steffen Bangsow, c Carl Hanser Verlag, Munich All rights reserved This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper Springer International Publishing AG Switzerland is part of Springer Science+Business Media (

4 Preface Based on the competition of international production networks, the pressure to increase the efficiency of production systems has increased significantly. In addition, the number of technical components in many products and as a consequence also the requirements for corresponding assembly processes and logistics processes increases. International logistics networks require corresponding logistics concepts. These requirements can be managed only by using appropriate Digital Factory tools in the context of a product lifecycle management environment, which allows reusing data, supports an effective cooperation between different departments, and provides up-to-date and relevant data to every user who needs it. Simulating the complete material flow including all relevant production, storage, and transport activities is recognized as a key component of the Digital Factory in the industry and as of today widely used and accepted. Cutting inventory and throughput time by 20 60% and enhancing the productivity of existing production facilities by 15 20% can be achieved in real-life projects. The purpose of running simulations varies from strategic to tactical up to operational goals. From a strategic point of view, users answer questions like which factory in which country suits best to produce the next generation product taking into account factors like consequences for logistics, worker efficiency, downtimes, flexibility, storage costs, etc., looking at production strategies for the next years. In this context, users also evaluate the flexibility of the production system, e.g., for significant changes of production numbers a topic which becomes more and more important. On a tactical level, simulation is executed for a time frame of 1 3 months in average to analyze required resources, optimize the sequence of orders, and lot sizes. For simulation on an operational level, data are imported about the current status of production equipment and the status of work in progress to execute a forward simulation till the end of the current shift. In this case, the purpose is to check if the target output for the shift will be reached and to evaluate emergency strategies in case of disruptions or capacities being not available unexpectedly. In any case, users run simulation to take a decision about a new production system or evaluate an existing production system. Usually, the value of those systems is a significant factor for the company, so the users have to be sure that they take the right decision based on accurate numbers. There are several random processes in real production systems like technical availabilities, arrival times of assembly parts, process times of human activities, etc., so stochastic processes play an important role for throughput simulation. Therefore, Plant Simulation provides a whole range of

5 VI Preface easy-to-use tools to analyze models with stochastic processes, to calculate distributions for sample values, to manage simulation experiments, and to determine optimized system parameters. Besides that, results of a simulation model depend on the quality of the input data and the accuracy of the model compared to the behavior of the real production system. As soon as assembly processes are involved, several transport systems with their transport controls, workers with multiple qualification profiles or storage logic, production processes become highly complex. Plant Simulation provides all necessary functionality to model, analyze, and maintain large and complex systems in an efficient way. Key features like object orientation and inheritance allow users to develop, exchange/reuse, and maintain their own objects and libraries to increase modeling efficiency. The unique Plant Simulation optimization capabilities support users to optimize multiple system parameters at once like the number of transporters, monorail carriers, buffer/storage capacities, etc., taking into account multiple evaluation criteria like reduced stock, increased utilization, increased throughput, etc. Based on these accurate modeling capabilities and statistic analysis capabilities, typically an accuracy of at least 99% of the throughput values is achieved with Plant Simulation models in real-life projects depending on the level of detail. Based on the price of production equipment, a return on investment of the costs to introduce simulation is quite often already achieved after the first simulation project. Visualizing the complete model in the Plant Simulation 3D environment allows an impressive 3D presentation of the system behavior. Logfiles can be used to visualize the simulation in a Virtual Reality (VR) environment. The support of a Siemens PLM Software unified 3D graphics engine and unified graphics format allows a common look-and-feel and easy access to 3D graphics which were created in other tools like digital product design or 3D factory layout design tools. The modeling of complex logic always requires the usage of a programming language. Plant Simulation simplifies the need to work with programming language tremendously by supporting the user with templates, with an extensive examples collection and a professional debugging environment. Compared to other simulation tools in the market, Plant Simulation supports a very flexible way of working with the model, e.g., by changing system parameters while the simulation is running. This book provides the first comprehensive introduction to Plant Simulation. It supports new users of the software to get started quickly, provides an excellent introduction how to work with the embedded programming language SimTalk, and even helps advanced users with examples of typical modeling tasks. The book focuses on the basic knowledge required to execute simulation projects with Plant Simulation, which is an excellent starting point for real-life projects. We wish you a lot of success with Tecnomatix Plant Simulation. November 2009 Dirk Molfenter Siemens PLM Software

6 Contents 1 Basics Introducing Material Flow and Logistics Simulation Uses Definitions Procedure of Simulation Formulation of Problems Test of Simulation-Worthiness Formulation of Targets Data Collection Modeling Executing Simulation Runs Result Analysis and Result Interpretation Documentation Plant Simulation: First Steps The Tutorial Step-by-Step Help Example Collections and Demo Videos The Siemens PLM Software Community Introductory Example First Simulation Example Insert Objects into the Frame Connect the Objects Define the Settings of the Objects Run the Simulation Modeling Object-Related Modeling Object-Oriented Modeling Student and Demo Version SimTalk and Dialogs The Object Method The Method Editor Line Numbers, Entering Text Bookmarks... 19

7 VIII Contents Code Completion Information about Attributes and Methods Templates The Debugger SimTalk Names Anonymous Identifiers Paths Absolute Path Relative Path Name Scope Comments Variables and Data Types Variables Local Variables Arrays Global Variables Operators Mathematical Operators Logical (Relational) Operators Assignments Branching Case Differentiation Loops Conditional Loops Header-Controlled Loops Footer-Controlled Loops For Loop Methods and Functions Passing Arguments Passing Several Arguments at the Same Time Result of a Function Predefined SimTalk Functions Method Call Sensors Other Events for Calling Methods Constructors and Destructors Drag and Drop Control Method Call after a Certain Timeout Recursive Programming Observer Interrupt Methods The Wait Statement Suspending of Methods... 58

8 Contents IX 2.11 Debugging, Optimization Breakpoints in Methods Breakpoints in the EventController Error Handler Profiler Hierarchical Modeling The Frame The Interface Create Your Own Libraries Dynamic Model Generation Required Data, SimTalk Language Elements Create Objects and Set Attributes Link Objects Dynamically with Connectors Connect Objects Dynamically with Lines Dialogs Elements of the Dialog The Dialog Object Callback Function The Static Text Box The Edit Text Box Images in Dialogs Buttons Radio Buttons Checkbox Drop-Down List Box and List Box List View Tab Control Group Box Menu and Menu Item Accessing Dialogs User Interface Controls Input Functions Output Functions Messagebox Infobox Bell and Beep HTML Window Modeling of Production Processes Material Flow Library Elements General Behavior of the Material Flow Elements Time Consumption Capacity

9 X Contents Blocking, Exit Behavior Failures ShiftCalendar SimTalk Attributes and Methods of the Material Flow Elements States of the Material Flow Elements Setup Finished Messages Finished Messages Using resworking Create Your Own Finished Messages Content of the Material Flow Objects Mobile Units (MUs) Standard Methods of Mobile Units Length, Width and Booking Point Entity and Container Source and Drain Basic Behavior of the Source Settings of the Source Source Control Using a Trigger User-defined Source with SimTalk The Drain Single Processing SingleProc, Fixed Chained Machines Batch Processing Simultaneous Processing of Several Parts The ParallelProc Machine with Parallel Processing Stations Continuous Machining, Fixed Transfer Lines The Cycle, Flexible Cycle Lines Assembly Processes The AssemblyStation Assembly with Variable Assembly Tables Use SimTalk to Model Assembly Processes Dismantling The DismantleStation Simulation of Split-Up Processes Dismantle Processes Using SimTalk Scrap and Rework The FlowControl Model Scrap Using the Exit Strategy Information Flow, Controls The List Editor One-Dimensional Lists

10 Contents XI The CardFile StackFile and QueueFile Searching in Lists The TableFile Methods and Attributes of the TableFile Searching in TableFiles Calculating within Tables Nested Tables and Nested Lists TimeSequence The Object TimeSequence TimeSequence with TableFile and SimTalk The Trigger The Object Trigger Trigger with SimTalk and TableFile The Generator The Generator Object User-defined Generator with SimTalk The AttributeExplorer The EventController Shop Floor Control, Push Control Base Model Machine Elements of the Job Shop Simulation Work Plans Order Management Resource Management Production Control Pull Control Simple Pull Control Kanban Functioning of the Kanban System Control Loops Modeling of a Single-Stage E-Kanban System Bin Kanban System Card Kanban System The Plant Simulation Kanban Library Line Production CONWIP Control Overall System Availability, Line Down Time Sequence Stability Working with Random Values Working with Distribution Tables Working with Probability Distributions Use of DataFit to Determine Probability Distributions

11 XII Contents Use of Uniform Distributions Set of Random Distributed Values Using SimTalk Warm-Up Time The ExperimentManager Simple Experiments Multi-level Experimental Design Generic Algorithms GA Sequence Tasks GA Range Allocation Simulation of Transport Processes The Line Attributes of the Line Curves and Corners AngularConverter and Turntable Settings of the AngularConverter Settings of the Turntable Turntable, Select User-defined Exit The Turnplate Basic Behavior of the Turnplate Settings of the Turnplate The Converter The Track Sensors on Length-Oriented Blocks Function and Use of Sensors Light Barrier Mode Create Sensors Automatically The Transporter Attributes of the Transporter Load and Unload the Transporter Using the AssemblyStation and the DismantlingStation Load and Unload the Transporter Using the TransferStation Load and Unload Transporter Using SimTalk SimTalk Methods and Attributes of the Transporter Stopping and Continuing Drive a Certain Distance Routing Automatic Routing Routing (Destination Lists) Routing with SimTalk Driving Control ( freestyle ) Sensorposition, Sensor-ID, Direction Start Delay Duration Load Bay Type Line, Cross-Sliding Car

12 Contents XIII 6.8 Tractor General Behavior Hitch Wagons to the Tractor Loading and Unloading of Trains Model Transporters with Battery Case studies The Plant Simulation Multi-Portal Crane Object Simulation of a Forklift Simulation of Robots and Handling Equipment PickAndPlace Attributes of the PickAndPlace Object Blocking Angle Time Factor Simulation of Robots Exit Strategy Cyclic Sequence Load and Unload of Machines (Single Gripper) Load and Unload of Machines (Double Gripper) PickAndPlace Loads Containers Assembly with Robots The Target Control of the PickAndPlace Object Consider Custom Transport and Processing Times Advantages and Limitations of the PickAndPlace Object Model Handling Robots Using Transporter and Track Basic Model and General Control Partial Parameterized Control Development Handling and Processing Times of the Robot Synchronous and Asynchronous Control of the Robot The LockoutZone Gantry Robots Warehousing and Procurement Buffer The Sorter Basic Behavior Attributes of the Sorter Sort by Method The Store, Warehousing The Store Chaotic Warehousing Inventory, Process of Storage Structure of the Inventory (Table Stock) Looking for a Free Place

13 XIV Contents Store and Register Parts Find a Part and Remove It from the Warehouse Virtual Warehousing Extension of the Store Class Search a Free Place, Store, Update Stock List Search for and Retrieval of Parts Stock Statistics Simplified Warehousing Model Warehouse Key Figures Storage Costs Economic Order Quantity Cumulative Quantities Procurement Warehousing Strategies Consumption-Based Inventory Replenishment Order Rhythm Method Reorder Point Method Goods Receipt Warehouse, Reorder Point Method Warehouse Retrievals Deliveries Inbound, Out-of-stock Part Visualization of the Database Stock Storage and Retrieval Orders Warehouse Statistics (Database) The StorageCrane Object Store and Remove Automatically with the StorageCrane Customized Storage and Retrieval Strategies Stock Statistics of the StorageCrane Object Load and Unload the Store with a Transporter Simulation of Workers Exporter, Importer and Broker Function Exporter and Broker Statistics Worker The Worker-WorkerPool-Workplace-FootPath Concept The Broker The WorkerPool The Worker The Footpath The Workplace Worker Transporting Parts

14 Contents XV 9.3 Worker Statistics Case Snippets for Worker Simulation Loading of Multiple Machines by One Operator The Worker Loads and Unloads Containers Chaku-Chaku Troubleshooting Depending on the Nature of the Failure Collaborative Work of Several Workers A Worker Executes Different Activities at One Station The Worker Changes Speed Depending on the Load Employees Working with Different Efficiency The Worker Loads Carriers and Transports Them Multiple-Machine Operation Worker Loads Machines on Availability Worker Works with Priority (Broker Importer Request Control) Determination of the Number of Workers with the ExperimentManager Modeling of Workers with Transporter and Track Modeling Approach The Worker Follows a Process The Worker Is Driving a Transporter The Fluids Library The Fluid Elements, Continuous Simulation The Tank Simple Case Studies Pumping Out Distribute Fluids Fill the Tank with a Tanker Unload a Tank Using a Tanker Separator Status Change D and 3D Visualization D Visualization The Icon Editor Inserting Images Insert Images from the Clipboard Inserting Images from a File Changing the Background of the Frame Animation Structures and Reference Points Set Reference Points Animation Structures Animating Frames

15 XVI Contents Dynamic Creation of 2D Animation Structures Simple 2D Icon Animations Plant Simulation 3D Introduction to Plant Simulation 3D Navigation in the 3D Scene Formatting 3D Objects Load 3D Graphics Transformations Animation Paths 3D D State Icons (LEDs) MU Animation Length-Oriented Objects in 3D Textured Plate D Animation Self-animations, Named Animations SimTalk 3D Animations, Unnamed Animations Camera Animations Attach Camera Camera Path Animations Manipulation of 3D Objects Integrate Energy Consumption and Costs Simulation of Energy Consumption Energy Consumption Basic Behavior Energy Profiles Energy Consumption in the Periphery of Machines Integrate Costs into the Simulation Production Concurrent Costing Working Assets Machine-Hour Rates Statistics Statistics Collection Period Statistics Methods and Attributes Write the Statistical Data into a File Determining Average Values Record Values Calculation of the Number of Jobs Executed Per Hour (JPH) Data Collected by the Drain Statistical Values of the Global Variable Statistics of the Transporter

16 Contents XVII 13.3 User Interface Objects The Chart Object Plotter Chart Statistics Wizard Histogram The Sankey Diagram The BottleneckAnalyzer The Display The Display Panel The Comment The Report Automatic Resource Report (Statistics Report) The Report Until V The HTML Report (V. 12) Data Exchange and Interfaces DDE with Plant Simulation Read Plant Simulation Data in Microsoft Excel Excel DDE Data Import in Plant Simulation Plant Simulation DDE Data Export to Excel Plant Simulation Remote Control DDE Hotlinks The COM Interface Read Data from Plant Simulation Write Data, Call Methods, Respond to Events The ActiveX Interface ActiveX and Excel ActiveX Data Objects (ADO, ADOX) Creating a New Access Database Integrating the Necessary Libraries Creating a Database Table Insert Data into a Table, Add Records Find and Display Records Updating Data The File Interface The ODBC Interface Setup an ODBC Data Source Read Data from a Database Write Data into a Database Delete Data in a Database Table SQL Commands

17 XVIII Contents 14.6 SQLite Interface Create Databases and Tables Working with SQLite Databases SQL Functions in SQLite The XML Interface Introduction in XML Read in XML Files into Tables The XML Interface Select Nodes and Read Values Changing Data in XML Files Subject Index