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

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.