Increasing demands on production require innovative solutions. Simulation solutions offer an effective means to significantly enhance manufacturing efficiency. Using Siemens Plant Simulation, both material flow simulation and virtual commissioning facilitate precise planning and optimization of production systems. Virtual modeling aids in shortening development times and reducing costs. Additionally, we illustrate how simulation technology contributes to the optimization of a fictional automated high-bay warehouse and its associated conveyor system.
Manufacturers and machine builders face increasingly higher demands in the design, installation, and commissioning of production machinery. Trends in the manufacturing industry, such as shorter product life cycles, a growing number of product variants, and companies seeking cost-efficient solutions in their production processes, require engineers to employ advanced software solutions and simulations during the planning and development phases.
Simulation solutions offer numerous advantages in various phases of machine design and development. This case study examines two specific types of simulations used for a fictional automated high-bay warehouse and its corresponding conveyor system.
One of the essential simulations is the material flow simulation, which helps precisely determine the optimal layout, control logic, and operating parameters of a machine or system. This simulation enables a detailed analysis of material movements within the system, identifies bottlenecks, and optimizes the distribution of resources. By virtually modeling the material flow, potential inefficiencies can be detected and corrected early on, leading to improved performance and smoother operations. Additionally, the simulation aids in planning adjustments and expansions to meet future requirements.
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After the planning for the warehouse is completed, the virtual commissioning can begin. During this phase, the system’s control program is developed and tested directly using a digital twin. By conducting this development in parallel with, or even before, the actual machine installation, the on-site commissioning time can be significantly reduced, saving valuable project time. This method allows potential problems to be identified and resolved in advance, making the overall implementation process more efficient and smoother.
Siemens Plant Simulation was used to optimize the system during the design phase. Specific requirements were defined, such as the ability of the warehouse robot to complete each picking operation within 30 seconds, as well as the need for redundancy in the conveyor system to ensure reliability in case of failures. Additionally, certain constraints were taken into account, including the size of the available area in the factory and the dimensions of the pallets.
The simulation was utilized to design both the layout and the control logic of the system, and to precisely coordinate the operating speeds of the conveyor belts and the warehouse robot. The software performs simulations faster than real-time, enabling the investigation of numerous scenarios in a short period. The data obtained from the simulation allows for well-informed, data-driven decisions about the system.
By using simulation solutions, manufacturers and machine builders can not only increase the efficiency of their production processes but also reduce development time and costs. The case study vividly demonstrates how simulations can contribute to the optimization of high-bay warehouses and conveyor systems.
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