Machine control level simulation of an AS/RS in the automotive industry

Abstract

This paper illustrates a case study of a PLC (Programmable Logical Controller) logic simulation in the car manufacturing industry. The case study is developed in order to simulate and verify the PLC control program for an automobile panel AS/RS. Because of increasing demand, the complexity of the supply system is rising in this industry. To cope with this problem, companies use AS (automated storage) and RS (retrieval system) systems, despite inherent logical complexities. Industrial automated processes use PLC code to control the AS/RS; however, control information and the control code (PLC code) are difficult to understand. Therefore, this paper suggests a PLC simulation environment, using 3D models and PLC code, which consists of real automobile manufacturing data. Data used in this simulation is based on 3D and logical models, using actual size and PLC signals, respectively. The environment resembles a real factory; users can verify and test the PLC code using the simulation prior to implementation of AS/RS. The developed simulation environment can be used to run AS/RS systems to reduce time and cost. INTRODUCTIONTo fulfill increasing customer demand for various requirements, small quantity batch production and JIT (Just in Time) systems have been introduced in modern industries. The production system information and logistics have to comprise a single body to introduce these systems and thus high-speed facilities and high-accuracy control are necessary. The AS/RS (Automated Storage and Retrieval System), a rapid logistic system in automated manufacturing systems, plays a significant role to carry out production of parts and allow flexibility in functional changes. An AS/RS is a combination of equipment and controls that handle, store, and retrieve materials as needed with precision, accuracy, and speed under a defined degree of automation. Systems vary from relatively simple, manually controlled order-picking machines operating in small storage structures to extremely large, computer-controlled storage/ retrieval systems totally integrated into a manufacturing and distribution process. The AS/RS is applied to increase production volume in automated manufacturing systems through automation of facility control and strengthening of stock control. Application of the technology of AS/RS is a kernel skill for the construction of automated logistics, FMS, and CIM. Systematical management of information is not easily realized in an AS/RS, because special control rules and communication code are utilized to control the AS/RS, which uses an exclusive controller (Han et al. 1987, Hausma et al. 1976).

Survey on the virtual commissioning of manufacturing systems

“…Most of automated manufacturing systems are controlled by a PLC (Programmable Logic Controller), which is currently the most suitable and widely employed industrial control technology [9,[27][28][29][30][31][32].…”