Seeking Guidance on Simulating Overloaded Conveyor Systems in FlexSim

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Marcus asked Apr 23, '24 Marcus commented Apr 27, '24

Seeking Guidance on Simulating Overloaded Conveyor Systems in FlexSim

Dear FlexSim Community,

I am currently working on a simulation project involving overloaded conveyor lines. These conveyor lines are typically segmented, as shown in the pic, with each segment capable of holding a single tray of goods. Each segment is individually controlled by a motor, and the presence of goods is detected at the end of each segment by photoelectric sensors. The conveyor line features transfer machines in the middle that can change the direction of the goods by lifting them.

test2.fsm

I have attempted to simulate this scenario using a non-accumulating conveyor in FlexSim, as per the attached file, but I am unable to make the goods move in the desired direction. I am seeking advice on how to achieve the intended directional movement or if there is a standard approach within FlexSim for simulating this type of conveyor system.

Here are the key features I am trying to simulate:
1. Transfer machines that can change the direction of goods by lifting them. (depending on type)

I would greatly appreciate any guidance or best practices that you could share. If there are any standard templates or examples within FlexSim that could serve as a starting point for this type of simulation, that would also be very helpful.

Software Version:

FlexSim 22.0.16

conveyor change direction decision poi

1713867281741.png (1.5 MiB)

test2.fsm (56.8 KiB)

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Attachments: Up to 12 attachments (including images) can be used with a maximum of 23.8 MiB each and 47.7 MiB total.

Joerg Vogel commented · Apr 23 at 10:46 AM

It is standard, what you request. Only lifting is not a default option, but you can delay a transfer. If you need an lift action then you do this with an photoeye.

tutorial:

https://docs.flexsim.com/en/22.0/Tutorials/AdditionalTools/Tutorial1Conveyors/ConveyorsOverview/ConveyorsOverview.html

Reference please see menu, too.

https://docs.flexsim.com/en/22.0/Reference/3DObjects/Conveyors/StraightCurvedConveyor/StraightCurvedConveyor.html

summarized suggestions

https://answers.flexsim.com/answers/32894/view.html

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Marcus Joerg Vogel commented · Apr 24 at 01:37 AM

the real layout

the flexsim layout

Hi Joerg,

Thank you for your assistance. I have reviewed the tutorial content, and while it was informative, I find that the examples provided do not precisely match the specific scenario I am trying to simulate. It's possible that I may not have fully grasped the concepts necessary to adapt the tutorial to my needs.

I have attached a diagram of the conveyor system I am working on, which represents a part of the actual layout. In this system, all the lateral conveyors are designed to function as transfer machines capable of moving goods laterally or longitudinally.

I am struggling with how to implement the segmented connection of these conveyors, especially at the points where they need to change direction laterally. I have observed that using control points does not seem to allow for the control of the conveyor's movement in the longitudinal or lateral direction as required.

Could you please provide further clarification or guidance on how to achieve the desired directional control for these transfer machines within the conveyor system?

Thank you for your time and assistance.

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1713922494648.png (3.4 MiB)

CSN Marcus commented · Apr 24 at 02:24 AM

Hi, please refer to the layout below, the conveyor logic has a relationship between whether the goods can be sent or not and the space, so usually the corners will be simulated with jacking transplanters or modeled with the direction of the main line.

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Answer 1 · 2024-04-24T02:41:18Z

David Seo answered Apr 24, '24 Marcus commented Apr 27, '24

@Marcus

test2_FK.fsm

If lifting means 'diverter', I applied only diverting time 3 sec without lifting animation.

I uploaded the model.

You can move the direction using DP and apply the divert time using station.

And you can make lifting and down animation using trigger at station.

test2-fk.fsm (58.2 KiB)

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Attachments: Up to 12 attachments (including images) can be used with a maximum of 23.8 MiB each and 47.7 MiB total.

Marcus commented · Apr 24 at 05:02 AM

Hi David,

Thank you for your previous assistance. Based on the model you provided and the feedback from @CSN, I have regenerated the simulation model, which is now operating as expected.

However, I still have some further doubts regarding the model behavior(test2-fk-1.fsm）:

1. As shown in the diagram, why does the Decision Point (DP1) require an advance grid to make a decision, while the same decision logic at DP2 does not seem to take effect?

2. At Station S1, if a tray is moving laterally, it operates normally for 3 seconds. However, if the tray is moving longitudinally, this operation does not occur (it does not stay for 3 seconds).

Could you please provide some insight into why these discrepancies might be happening?

Thank you in advance for your continued support.

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1713934389685.png (383.1 KiB)

test2-fk-1.fsm (77.7 KiB)

Felix Möhlmann Marcus commented · Apr 24 at 06:20 AM

In the model you uploaded, DP2 (DP24) currently does not have any trigger functions set.

An issue you might be running into, is that an item can no longer be diverted to a side transfer if its leading edge has already passed the (center of the) transfer point.

You can change the settings on the DP to trigger the arrival when the leading edge of the item passes it, so it's still early enough to divert to the side.

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capture2.png (6.4 KiB)

Marcus Felix Möhlmann commented · Apr 24 at 06:59 AM

Comparison when changing decision point
Left: use the dp in advance grid; Right: use dp in the changing grid and set it to leading edgeleading edge and same triggers by case

Thank you for your previous assistance. I have attempted to modify the decision point's trigger to coincide with the point of turn on the conveyor, and also switched to using the "leading edge" trigger method. However, the conveyor is not operating as intended with this setup. It seems that the "leading edge" trigger is not activating as expected. I am wondering if there might be something I have overlooked.test2-fk-1.fsm

Could you please advise if there are additional factors I should consider or settings I need to adjust?

Thank you for your continued support.

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test2-fk-1.fsm (79.2 KiB)

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