A traditional warehouse is a commercial building for storage of goods. Modern warehouses are much more than that, they are completely automated, and require operators only to work and handle all the tasks while sitting in front of a computer. Pallets and product move on a system of automated conveyors, cranes and automated storage and retrieval systems coordinated by Programmable Logic Controllers and computer running logistics automation software. These systems are often installed in refrigerated warehouses where temperatures are kept very cold to keep the product from spoiling and where long human exposures are dangerous, e.g. in electronics warehouse where they require specific temperature to avoid damaging the parts or in cold storages which preserve agricultural products. Refrigerated storage helps in eliminating sprouting, rotting and insect damage. Automated warehouses also find their place where land is expensive, as automated storage systems can use vertical space efficiently. In addition, consolidating inventories, improving accuracy, increasing productivity, reducing operating costs, improving customer service label and accommodating growth are some of the other reasons that have made the industry opt for automation for the warehouses. In this thesis, the complete automation of one such state-of-the-art self-supporting warehouse is presented. The complete automation of the warehouse was realized by using 2 Automatic Storage and Retrieval Machines (ASRMs), 4 Elevators / Lifters, 20 AutosatMovers carrying 20 Supercap Autosats and a wide range of roller / chain conveyor systems. The Logic Control is developed with the help of a range of Siemens PLCs (Master-Slave) on Simatic Step 7 platform while as the Motion Control part is accomplished using various Sinamics Drives on Simotion Scout platform. This separation is done because, from the hardware point of view a powerful dedicated Control Unit for the Motion Control results in better results and from the software point of view, separating the logic control task for automation and Motion Control task for motorized axes yields higher efficiency of the PLC as well as the Drive. The inter-device communication is realized over a PROFINET based network with separate communication network for Motion Drives so as to increase the transmission rate for motor control and many more benefits discussed in this thesis. The SINAMICS – SIMOTION based controllers introduce OOP (Object Oriented Programming) concept in the drive control, rendering an easy application of motion synchronization between multi axis. Human Machine Interface for each machine is developed in this project using a portable HMI panel on TIA Portal platform.
Un magazzino tradizionale è un edificio commerciale per lo stoccaggio delle merci. Magazzini moderni sono molto più di questo, essi sono completamente automatizzati, e richiedono agli operatori solo per lavorare e gestire tutti i compiti, seduti davanti a un computer. Pallet e prodotto mossa su un sistema di nastri trasportatori automatizzati, gru e sistemi di stoccaggio e prelievo automatici coordinati da programmabili logici controllori (PLC) e computer con software per l'automazione della logistica. Questi sistemi sono spesso installati in celle frigorifere dove la temperatura sono tenuta molto fredda per mantenere il guastarsi di prodotto e dove esposizioni prolungate umani sono pericolose, ad esempio nel magazzino di elettronica in cui hanno bisogno di temperatura specifica per evitare di danneggiare le parti o in celle frigorifere, che la conservazione dei prodotti agricoli. Stoccaggio refrigerato aiuta ad eliminare germinazione, marciume e danni da insetti. Magazzini automatici anche trovare il loro posto dove la terra è costoso, come sistemi di stoccaggio automatici possono utilizzare lo spazio in verticale in modo efficiente. Inoltre, il consolidamento delle scorte, migliorando la precisione, aumentando la produttività, riducendo i costi operativi, migliorando l'etichetta servizio clienti e accomodante di crescita sono alcune delle altre ragioni che hanno reso l'opt settore per l'automazione dei magazzini. In questa tesi, la completa automazione di un state-of-the-art magazzino autoportante è presentato. La completa automazione del magazzino è stato realizzato utilizzando 2 Automatic Storage and Retrieval Machines (ASRMs), 4 Elevators / Lifters, 20 AutosatMovers che trasportano 20 Supercap Autosats e una vasta gamma di sistemi di trasporto a rulli / catena. La logica di controllo è stato sviluppato con l'aiuto di una serie di Siemens PLC (Master-Slave) sul piattaforma di Simatic Step 7, mentre la parte Motion Control viene eseguita utilizzando diversi azionamenti SINAMICS su piattaforma di Simotion Scout. Tale separazione avviene perché, dal punto di vista hardware potente unità di controllo dedicata per il controllo del movimento si traduce in migliori risultati dal punto di vista software, separando l'attività di controllo logica di automazione e di Motion Control per assi motorizzati produce maggiore efficienza del PLC e il Drive. La comunicazione inter-device è realizzato in una rete basata PROFINET con rete di comunicazione separata per Motion Drives in modo da aumentare la velocità di trasmissione per il controllo del motore e molti altri vantaggi discussi in questa tesi. Controllori basati su SINAMICS – SIMOTION introducono OOP concetto (Object Oriented Programming) nel controllo di unità, rendendo una facile applicazione di sincronizzazione dei movimenti tra i multi-asse. Human Machine Interface per ogni macchina è sviluppata in questo progetto con un mobile panel sulla piattaforma TIA Portal.
Design and implementation of a fully automated self supporting warehouse
SIDDIQUI, RAOUF UL MUAZZAM
2015/2016
Abstract
A traditional warehouse is a commercial building for storage of goods. Modern warehouses are much more than that, they are completely automated, and require operators only to work and handle all the tasks while sitting in front of a computer. Pallets and product move on a system of automated conveyors, cranes and automated storage and retrieval systems coordinated by Programmable Logic Controllers and computer running logistics automation software. These systems are often installed in refrigerated warehouses where temperatures are kept very cold to keep the product from spoiling and where long human exposures are dangerous, e.g. in electronics warehouse where they require specific temperature to avoid damaging the parts or in cold storages which preserve agricultural products. Refrigerated storage helps in eliminating sprouting, rotting and insect damage. Automated warehouses also find their place where land is expensive, as automated storage systems can use vertical space efficiently. In addition, consolidating inventories, improving accuracy, increasing productivity, reducing operating costs, improving customer service label and accommodating growth are some of the other reasons that have made the industry opt for automation for the warehouses. In this thesis, the complete automation of one such state-of-the-art self-supporting warehouse is presented. The complete automation of the warehouse was realized by using 2 Automatic Storage and Retrieval Machines (ASRMs), 4 Elevators / Lifters, 20 AutosatMovers carrying 20 Supercap Autosats and a wide range of roller / chain conveyor systems. The Logic Control is developed with the help of a range of Siemens PLCs (Master-Slave) on Simatic Step 7 platform while as the Motion Control part is accomplished using various Sinamics Drives on Simotion Scout platform. This separation is done because, from the hardware point of view a powerful dedicated Control Unit for the Motion Control results in better results and from the software point of view, separating the logic control task for automation and Motion Control task for motorized axes yields higher efficiency of the PLC as well as the Drive. The inter-device communication is realized over a PROFINET based network with separate communication network for Motion Drives so as to increase the transmission rate for motor control and many more benefits discussed in this thesis. The SINAMICS – SIMOTION based controllers introduce OOP (Object Oriented Programming) concept in the drive control, rendering an easy application of motion synchronization between multi axis. Human Machine Interface for each machine is developed in this project using a portable HMI panel on TIA Portal platform.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/126361