International conference on Computer Aided Design and Manufacturing

CADAM 2007
TRANSPORT SIMULATION OF HOUSINGS FOR WASHING
MACHINES ASSEMBLY

Šamec, B.; Potrč, I.; Šraml, M.; Lerher, T.; Počivavšek, T.

Abstract: In this paper, transport simulation of housings for washing machines assembly, is
presented. Assembly line is supplied by power and free overhead conveyor system. Along with
transportation purpose it also has a function as a buffer of housings for washing machines.
During operation, bottlenecks appear on production line. Therefore purpose of this simulation is
to compare actual capacity with optimal possible, on existing system.

Keywords: Material handling, Internal transport, Power and free, Buffers, Simulations.

1 INTRODUCTION
In mechanical engineering, simulations are used for precise planning of production and
assembly lines, working spots and setting up entire company together with supply
chain. Simulation model of a production line enables us to calculate needed amount of
material, time or working force. It also helps us to detect bottlenecks and weak points
of production line and helps us to foresee situation at various breakdowns or extreme
circumstances.
In this paper, transport simulation of housings for washing machines assembly at
the production line, is presented. Problem occurred in a company that already has a
power and free (P&F) conveyor system. Along with transportation purpose it also has
a function as a buffer of housings for washing machines. During operation of this P&F
conveyor system, a bottleneck on production line occasionally appears. Purpose of this
analysis is to represent material flow with computer simulation and to compare actual
efficiency with optimal possible on the existing P&F system.
2 PROBLEM FORMULATION
Power & free conveyor system was analyzed with computer simulation. Classical
analysis with analytical methods would be too difficult. Simulation was done with
AutoMod software [1]. Model was made with Power and Free module in AutoMod,
which enable us to simulate P&F conveyor systems, towlines, etc.
The main difference between P&F system and conveyor system is that in a P&F
system, carriers move around and pick up loads, while in conveyor systems, loads
move around on the conveyor. To simulate P&F system (Fig. 1) several tasks must be
accomplished: drawing sections, placing stations and photoeyes, creating motors and
carriers, and defining scheduling lists. Our model consists out of several sections,
transfers and stations.
Simulated P&F system is composed out of three sections for which attributes such
as speed, carrier accumulation, and carrier spacing can be changed. All three sections
together compose complete P&F conveyor system as in reality.
 Transfers allow a carrier to move from one section of a chain to another. Standard
motor is automatically assigned to each section. It can be used as a switching element
to start or stop individual section. Speed and acceleration can be changed during
simulation.
Stations are points on a chain at which loads can enter, process, and leave a power
& free system. To limit the number of carriers that can travel on a section, capacity of
stations can be set. Stations must be placed on chains. Name, type, enroute limit and
capacity must be set to define a station.

Fig. 1. Power & free simulation

5 CONCLUSION
In this paper, transport simulation of housings for washing machines assembly on
production line is presented. Purpose of this simulation was to compare actual capacity
with optimal possible on an existing power & free conveyor system. Computer
simulation allows us to conduct extensive optimization analyses. It enables us to
perform “what if” tests with same or modified parameters as in reality, without
interfering with actual system or when designing a new one.

References:

[1] Brooks Automation, Inc. (2003). AutoMod User’s Guide

Author(s): Šamec Blaž and Potrč Iztok, University of Maribor, Faculty of Mechanical
Engineering, Smetanova ulica 17, SI-2000 Maribor, Slovenia, phone +386 2 220 7500,
email: blaz.samec@uni-mb.si, iztok.potrc@uni-mb.si.