JP6856144B2 - Simulation system and simulation method - Google Patents

Description

The present invention relates to a simulation system for deriving the processing capacity of a transport system including a plurality of types of transport devices by simulation.

The transport system installed in a distribution center or the like is equipped with a combination of an automated warehouse equipped with a stacker crane and shelves, a conveyor, and an automatic guided vehicle with or without a track as a transport device for transporting cargo. Conventionally, in order to achieve the optimum control of the transport system, the transport simulation of the load corresponding to the transport system has been executed at any time to construct the transport system.

Patent Document 1 describes a simulation system in which the layout of a transfer device can be easily changed, simulation can be executed in a short time even with a complicated layout, and information on the processing capacity of the transfer system is calculated as a result value. It is disclosed.

JP-A-2017-84080

In the above simulation, in the layout of the transport device set arbitrarily, the transport state of the load is simulated using a predetermined model, and the processing capacity of the transport system is calculated as the result value.

When the above simulation program is used, the simulation is executed based on the layout of the transfer device set arbitrarily. Based on the simulation result, change the transfer device, change the layout, etc., and execute the simulation again. By repeating these steps, an optimum transfer system that achieves a desired processing capacity is constructed.

However, since there are multiple types of simulation models, it is necessary to select the optimum simulation program based on abundant expertise in simulation in order to obtain the optimum simulation results for constructing a transfer system. Therefore, not everyone can easily construct an optimum transfer system by making full use of simulation. Moreover, even if a simulation model can be selected, the scale of the transfer system has become large and complicated these days, and it is difficult to construct an optimum transfer system in a short time.

The present invention has been made in view of the above problems, and even a large-scale and complicated transfer system can execute a simulation in a relatively short time, and abundant information for constructing a transfer system can be obtained. The purpose is to provide a simulation system that can be provided.

In order to achieve the above object, the simulation system, which is one of the present inventions, includes a plurality of execution units for calculating information on the processing capacity of a transfer system including a plurality of types of transfer devices, and each of the plurality of execution units. The optimization unit is provided with an optimization unit that exchanges information between the two, and the plurality of execution units execute simulations based on mutually different mathematical formulas. The optimization unit is based on the simulation result of the execution unit. A judgment unit that acquires a certain result value and determines whether or not the acquired result value satisfies a predetermined judgment condition, and when the judgment unit determines that the judgment condition is not satisfied, the above-mentioned is performed based on the result value. When it is determined that the execution instruction unit that causes the execution unit different from the execution unit or the same execution unit to execute the simulation and the judgment unit satisfy the judgment conditions, the result value calculated by each execution unit is transferred to the transport system. It is equipped with an output unit that outputs as the processing capacity of.

According to this, since each execution unit performs simulations of different models under controlled conditions while providing information to each other, highly accurate information on the processing capacity required for constructing a transfer system can be obtained in a relatively short time. We can provide abundantly. Further, even if the operator who operates the simulation system does not have deep knowledge about the simulation, it is possible to provide the information necessary for constructing the transfer system.

Further, a reception unit that receives the input layout of the transfer device as layout information, and an information generation unit that generates information for at least one execution unit to execute a simulation based on the layout information received by the reception unit. The execution instruction unit may cause the execution unit selected based on the information generated by the information generation unit to execute the simulation.

As a result, even an operator who does not know in detail the information initially used by the execution unit for each transfer device can acquire information indicating the processing capacity of the transfer system simply by inputting the layout of the transfer device. it can.

Further, the determination unit has an individual condition that the result value calculated by the execution unit is equal to or greater than the threshold value corresponding to the same execution unit or less than the threshold value corresponding to the same execution unit, and a predetermined number of the above-mentioned determination units are used. When the results calculated by the execution unit satisfy the individual conditions, it may be determined that the judgment conditions are satisfied. Further, the determination unit has an individual condition that the newly calculated result value does not change with respect to the previously calculated result value in the same execution unit, and a predetermined number of the calculation result values of the execution unit are obtained. May be judged to have satisfied the judgment condition when the individual condition is satisfied.

In addition, all the execution units may execute the simulation based on the mathematical model.

According to this, it is possible to quickly acquire the result value indicating the processing capacity of the transport system.

Further, one of the execution units may execute the simulation according to the queuing theory, and the other one of the execution units may execute the simulation according to the scheduling theory.

According to this, it is possible to obtain a queue and a Gantt chart that can effectively cost the processing capacity of the transport system.

Further, a search unit for identifying and notifying one of the transport devices having the greatest influence on the simulation result executed by the execution unit is further provided.

According to this, it can be suitably used when changing the layout of the transport device, and helps to construct a better layout.

It should be noted that the implementation of the present invention also corresponds to the implementation of a program for causing a computer to execute each process included in the simulation system. Of course, implementing a recording medium on which the program is recorded also corresponds to the implementation of the present invention.

According to the present invention, abundant information on the processing capacity of the transport system can be obtained by simulation in a relatively short time.

It is a block diagram which shows the functional structure of the simulation system which concerns on embodiment. It is a figure which shows one output example which was output to the display device by the output part which concerns on embodiment. It is a figure which shows the other output example which was output to the display device by the output part which concerns on embodiment. It is a figure which shows the screen which displayed the graphical connection state based on the reception part which concerns on embodiment. It is a flowchart which shows the operation flow of the simulation system which concerns on embodiment. It is a figure which shows the screen which displayed the graphical connection state based on the reception part in another example.

Next, an embodiment of the simulation system according to the present invention will be described with reference to the drawings. The following embodiments are merely examples of the simulation system according to the present invention. Therefore, the present invention is defined by the wording of the claims with reference to the following embodiments, and is not limited to the following embodiments. Therefore, among the components in the following embodiments, the components not described in the independent claims indicating the highest level concept of the present invention are not necessarily necessary for achieving the object of the present invention, but more. Described as constituting a preferred form.

In addition, the drawings are schematic views in which emphasis, omission, and ratio are adjusted as appropriate to show the invention of the present application, and may differ from the actual shape, positional relationship, and ratio.

(Embodiment)
FIG. 1 is a block diagram showing a functional configuration of a simulation system. The simulation system 100 is a system that executes a simulation related to the transportation of a load and derives the processing capacity of the transportation system for a transportation system including a plurality of types of transportation devices, and includes a plurality of execution units and an optimization unit 120. There is. In the case of the present embodiment, the simulation system further includes a reception unit 131, an information generation unit 132, and a storage unit 101.

Further, in the case of the present embodiment, the simulation system will be described as having a CPU (Central Processing Unit) and realizing each functional unit by executing a program stored in the storage unit 101 by the CPU.

In addition, the transport device provided in the transport system to be simulated includes a case conveyor that mainly transports luggage such as a case in the horizontal direction, a pallet conveyor that mainly transports pallets that integrally hold a plurality of luggage in the horizontal direction, and a stacker. An automated guided vehicle that combines a crane and a shelf that holds luggage, a sorter that sorts luggage, an automated guided vehicle that transports luggage along rails, an automated guided vehicle that travels on the floor without rails, and transports luggage. An example is a picking station in which a predetermined number of products are picked up from luggage by a car, a person, or a robot according to an order, a plurality of products are collected, stored in another luggage, and carried out. In addition, the transport device also includes a disassembling device for taking out the load from the pallet. In addition, processing equipment such as painting equipment and inspection equipment also process and inspect the luggage that has been brought in, then carry out the luggage and temporarily store (buffer) multiple luggage. Therefore, in the simulation system 100, it is treated as one of the transport devices.

The execution unit has the processing capacity of a transport system consisting of a plurality of transport devices virtually laid out and interconnected, specifically, how many packages are received within a unit time and within the transport system within a unit time. It is a processing unit that simulates the processing capacity of how many packages can be transported and buffered and how many packages can be carried out within a unit time according to different mathematical models (mathematical formulas). In the case of the present embodiment, the simulation system 100 includes a first execution unit 111 and a second execution unit 112 as execution units.

The first execution unit 111 is a processing unit that executes a simulation using queuing theory. Variables used in the first execution unit 111 include, for example, the number of transport devices provided in the transport system, the capacity of each transport device, the buffer of each transport device, the arrival rate of each transport device, the service rate of each transport facility, and the like. is there.

As the result value of the simulation execution of the first execution unit 111, for example, the effective arrival rate of each transfer device, the effective service rate of each transfer device, and the steady state in the connected state of the predetermined transfer device and the transfer devices connected before and after the predetermined transfer device. State establishment, etc.

The second execution unit 112 is a processing unit that executes a simulation using the scheduling theory. The variables used in the second execution unit 112 include, for example, the location of the picking station, which is one of the transport devices, the input buffer capacity of the picking station, the output buffer capacity, the transport, and the waiting for work, so that the load is retained. Number of gates indicating the number of gates to be used, picking processing time, time to move from input buffer to next input buffer, time to move from output buffer to next output buffer, time to move from one gate to the next, For example, the time when the order was generated.

The first execution unit 111 can execute the simulation using at least one of the result value calculated by the second execution unit 112 and the information acquired from the information generation unit 132, and the second execution unit 112 can execute the simulation. (1) The simulation can be executed using at least one of the result value calculated by the execution unit 111 and the information acquired from the information generation unit 132.

The result value of the simulation execution of the second execution unit 112 is, for example, the processing start time of the order at each picking station.

The optimization unit 120 is a processing unit that exchanges information between the execution unit and the execution unit so that the result values calculated by the plurality of execution units become the optimum values. The determination unit 121, the execution instruction unit 122, and the output unit 120. It is provided with a unit 123. In the case of this embodiment, the optimization unit 120 includes a search unit 124. The optimization unit 120 includes a holding unit that stores at least one of the information generated by the information generation unit 132, the result value calculated by the first execution unit 111, and the result value calculated by the second execution unit 112. .. The holding unit may overwrite when the same type of result value is input, or may hold a predetermined amount of information and delete the oldest information when overflowing. Further, the optimization unit 120 can appropriately output the information stored in the holding unit to at least one of the first execution unit 111 and the second execution unit 112.

The determination unit 121 is a processing unit that acquires a result value that is a simulation result of any one of the plurality of execution units and determines whether or not the acquired result value satisfies a predetermined determination condition. The judgment conditions, which are the criteria for the judgment unit 121 to make a judgment, are not particularly limited, and vary depending on the type and purpose of the corresponding transport system. Further, since the simulation model of each execution unit is different, the judgment unit 121 determines the result value calculated by each execution unit under each individual condition, and the summarization of each judgment result with respect to the result value of each execution unit is obtained. Judgment may be made based on whether or not the judgment condition is satisfied. In this case, the determination unit 121 uses as many individual conditions as the number of execution units and determination conditions for comprehensively determining whether or not the individual conditions are satisfied. In the case of the present embodiment, the determination unit 121 includes a first individual condition corresponding to the first execution unit 111, a second individual condition corresponding to the second execution unit 112, and a determination condition for summarizing these. ..

Specifically, for example, the determination unit 121 determines that the result value calculated by the first execution unit 111 is equal to or greater than the threshold value corresponding to the first execution unit 111 or less than the threshold value corresponding to the first execution unit 111. One individual condition, and the second individual condition is that the result value calculated by the second execution unit 112 is equal to or more than the threshold value corresponding to the second execution unit 112 or less than the threshold value corresponding to the second execution unit 112. When the result calculated by the first execution unit 111 satisfies the first individual condition and the second execution unit 112 satisfies the second individual condition, it is determined that the determination condition is satisfied.

Further, the determination unit 121 sets that the first individual condition is that the newly calculated result value does not change with respect to the previously calculated result value in the first execution unit 111, and the second execution unit 112 newly calculates the result value. The second individual condition is that the calculated result value does not change with respect to the previously calculated result value, and the result value calculated by the first execution unit 111 and the result value calculated by the second execution unit 112 are When each individual condition is satisfied, it may be determined that the judgment condition is satisfied.

The determination unit 121 may determine whether or not the determination condition is satisfied based on only some result values in the execution unit, instead of determining using the result values of all the execution units. .. For example, when determining only the result value of one execution unit, the individual condition and the determination condition match.

When the determination unit 121 determines that the determination condition is not satisfied, the execution instruction unit 122 executes the simulation to another or the same execution unit different from the execution unit that calculates the result value based on the acquired result value. It is a processing unit to be made to. Which execution unit the execution instruction unit 122 causes to execute the simulation is not particularly limited, but for example, the order of the execution units that execute the simulation is predetermined, and the execution instruction unit 122 has the determined order. The execution may be instructed according to the above. Further, since the acquired result information does not satisfy the individual conditions, the execution instruction unit 122 sets the acquired result value to the acquired result value, such as causing the same execution unit to execute the simulation until the individual conditions are satisfied. Based on this, the execution unit for executing the simulation may be dynamically determined.

In the case of the present embodiment, for example, when the determination condition is not satisfied by the result value calculated by the second execution unit 112, some of the result values calculated by the second execution unit 112 are first. When the variable of the execution unit 111 is input to the first execution unit 111, the first execution unit 111 executes the simulation, and the judgment condition is not satisfied depending on the result value calculated by the first execution unit 111. Some of the result values calculated by the first execution unit 111 are input to the second execution unit 112 as variables of the second execution unit 112, and the second execution unit 112 is made to execute the simulation.

Specifically, for example, when the judgment condition is not satisfied because the result value calculated by the first execution unit 111 based on the queuing theory does not satisfy the first individual condition, the maximum number of buffers which is one of the calculated result values. Is input as the input buffer capacity of the second execution unit 112.

On the other hand, the start time, end time, etc. of each transfer device, which are the result values calculated by the second execution unit 112 based on the scheduling theory, are input to the first execution unit 111.

The output unit 123 is a processing unit that outputs the result value finally calculated by each execution unit to the display device 210 or the like as the processing capacity of the transfer system when the determination unit 121 determines that the determination condition is satisfied. 2 and 3 are diagrams showing an example of output output to the display device by the output unit. The output unit 123 creates and displays a table in which the queue, which is the final output result value of the first execution unit 111, is associated with the transfer device (see FIG. 2), and the second execution unit 112 Based on the calculated result, a Gantt chart including the transport capacity of each transport device is created and displayed.

The search unit 124 is a processing unit that identifies and notifies at least one of the transport devices that has the greatest influence on the simulation result executed by the execution unit by the search. In the case of this embodiment, the output unit 123 outputs. In the case of the present embodiment, the output unit 123 notifies the searched transport device using a table, a figure, a chart, or the like created for display. Specifically, as shown in FIG. 2, since the conversion machine 2 has the largest number of queues and is a transfer device that has the greatest impact on the entire transfer system, it is notified by highlighting it together with the corresponding number of queues. There is.

The storage unit 101 is a storage device that stores variables and the like that are information related to the processing capacity of each transfer device. The storage unit 101 is a device that stores a simulation program or the like corresponding to the execution unit, which is one of the programs executed by the CPU, and is composed of storage elements such as a ROM (Read Only Memory) and a hard disk. There is.

The variables stored in the storage unit 101 are not particularly limited, but for example, (a) control parameters of each transfer device such as speed, acceleration / deceleration, and operation timer value, (b) number of transfer devices, and (c). ) The transfer device, the transfer to the picking operator, the allocation control logic for determining the transfer instruction, (d) the number of buffers described in the transfer layout, the transfer route length, (e) how to flow the transported object, etc. be able to.

The reception unit 131 is a processing unit that receives the input layout of the transport device as layout information. In the case of the present embodiment, as shown in FIG. 1, the reception unit 131 graphically receives the connection between the output of one transfer device stored in the storage unit 101 and the input of another transfer device. The reception unit 131 displays the first icon 221 corresponding to the type of the transfer device, and receives the connection of the transfer device by graphically connecting the first icon 221 on the screen of the display device 210.

Specifically, the interface 220 drags a plurality of first icons 221 arranged side by side on the right edge of the screen to the connection screen 229 provided on the left, and the first icons arranged first on the connection screen 229. By arranging so that the IN of the first icon 221 dragged to the OUT of 221 is connected, the reception unit 131 receives the connection between the output and the input of the transport device corresponding to the first icon 221.

Here, the alphabet described in the first icon 221 is as follows in the case of the present embodiment. That is, CCV: case conveyor, PCV: pallet conveyor, AWH: automated warehouse, S: sorter, RGV: automatic guided vehicle, AGV: automatic guided vehicle on the floor, DM: disassembling device.

The information generation unit 132 is a processing unit that generates information for executing a simulation by at least one execution unit based on the layout information received by the reception unit 131. The information generated by the information generation unit 132 is not particularly limited, but for example, the processing time (transport time) of each transport device, the transport start time of each transport object, the transport end time of each transport object, and each transport object. It is possible to indicate the residence (congestion) time of the vehicle. In the case of the present embodiment, the information is generated by extracting the information corresponding to each transfer device received by the reception unit 131 from the storage unit 101, and the information is provided to the execution instruction unit 122. The execution instruction unit 122, which has acquired information from the information generation unit 132, uses the acquired information as an initial condition and is either a predetermined execution unit or an execution unit selected as conforming to the initial condition. To run the simulation by providing the initial conditions.

Next, an example of a specific operation of the simulation system 100 will be described based on the flowchart shown in FIG.

The operator draws the layout of the transport system via the interface 220 (S101). The information generation unit 132 generates information used for simulation such as the transfer capacity and transfer speed of the transfer device included in the drawn layout based on the table stored in the storage unit 101 and the like. Further, the transfer device not registered in the table or the transfer device whose specifications have been changed may be input by the operator via the interface 220 and accepted by the reception unit 131. Further, the information generation unit 132 determines the connection state of the transfer device based on the drawn layout and generates information necessary for the simulation (S102). At this stage, the operator can add, modify, delete, etc. the information.

Next, the execution instruction unit 122 of the optimization unit 120 first determines which execution unit to execute the simulation based on the information generated by the information generation unit 132, and provides the determined execution unit with the information. The simulation is executed based on (S103). The execution unit that first executes the simulation is not particularly limited, and may be selected in advance or with a predetermined probability. In the case of this embodiment, it is predetermined that the first execution unit 111 executes the initial simulation.

Next, the simulation is executed in the execution unit instructed by the execution instruction unit 122 (S104), and the determination unit 121 determines whether the calculated result value satisfies the determination condition (S105). It should be noted that the determination condition is not satisfied until all of the plurality of execution units or the result values of the predetermined plurality of execution units are obtained.

Next, when the determination unit 121 determines that the determination condition is not satisfied, the execution instruction unit 122 determines the execution unit to execute the simulation next (S106), and determines the newly acquired result value. To instruct to execute the simulation. The execution unit that receives the instruction executes the simulation using the provided result value as a variable or the like (S104).

On the other hand, when the determination unit 121 determines that the determination condition is satisfied, the output unit 123 converts the result value finally calculated by each execution unit into the processing capacity of the transport system, and the operator such as a table or a Gantt chart. It is converted into information that is easy to understand (see FIGS. 2 and 3) and output to the display device 210 (S107).

Next, when the processing capacity is output, the search unit 124 acquires the variables in at least one execution unit when the processing capacity is calculated, and the transport device has the greatest influence on the simulation result executed by the execution unit. At least one of the above is specified by a search, and the corresponding transport device and its variables are notified (S108). The notification method is not particularly limited, and for example, the information to be notified may be superimposed on the information such as the table and the Gantt chart generated by the output unit 123. Further, the information to be notified may be superimposed and shown on the layout diagram drawn in S101.

Finally, the display device 210 displays an image showing the processing capacity and showing the bottleneck portion (S109).

According to the above simulation system 100, a plurality of execution units that execute simulations with different types of simulation models are provided, and the result values that are the results of the simulations are mutually used as variables for the simulation, resulting in a complicated layout. It is possible to calculate the processing capacity with high accuracy even with the transfer system of.

Further, since the simulation is executed from different viewpoints, a large amount of information for the transfer system can be output, and it is possible to effectively contribute to the determination of the layout of each transfer device.

Further, since the bottleneck can be searched for and notified based on a large amount of information on the transport system, it is possible to provide effective information for layout rearrangement of the transport device.

The invention of the present application is not limited to the above-described embodiment. For example, another embodiment realized by arbitrarily combining the components described in the present specification and excluding some of the components may be the embodiment of the present invention. In addition, the present invention also includes modifications obtained by making various modifications that can be conceived by those skilled in the art within the scope of the gist of the present invention, that is, the meaning indicated by the wording described in the claims, with respect to the above-described embodiment. Is done.

For example, the layout information received by the reception unit 131 may be as simple as shown in FIG.

Further, although the case where there are two execution units has been described, the simulation system 100 may include three or more execution units.

The present invention can be used for designing a transport system that automatically transports a package by combining a plurality of transport devices such as a distribution base and a production factory.

100 Simulation system 101 Storage unit 111 First execution unit 112 Second execution unit 120 Optimization unit 121 Judgment unit 122 Execution instruction unit 123 Output unit 124 Search unit 131 Reception unit 132 Information generation unit 210 Display device 220 Interface 221 First icon 229 Connection screen

Claims (7)

Multiple execution units that calculate information about the processing capacity of a transport system equipped with multiple types of transport devices,
It is equipped with an optimization unit that exchanges information with each of the plurality of execution units.
The plurality of said execution units
Simulations are executed based on different mathematical formulas to derive different types of result values.
The optimization unit
Whether or not the result value that is the simulation result of any of the plurality of execution units is acquired and the acquired result value satisfies the judgment condition that is the individual condition corresponding to the execution unit from which the result value is acquired. Judgment department to judge whether
When it is determined that the determination unit does not satisfy the determination condition, an execution instruction unit that causes the execution unit different from or the same as the execution unit to execute the simulation based on the result value, and an execution instruction unit.
A simulation system including an output unit that outputs a result value calculated by each execution unit as the processing capacity of the transport system when the determination unit determines that the determination condition is satisfied. The simulation system according to claim 1, wherein the execution instruction unit gives an execution instruction in a predetermined order of the execution unit that executes the simulation. A reception unit that accepts the input layout of the transport as layout information,
At least one execution unit includes an information generation unit that generates information for executing a simulation based on the layout information received by the reception unit.
The execution instruction unit
The execution unit selected based on the information generated by the information generation unit is made to execute the simulation.
The execution unit
Run the simulation based on the mathematical model,
One of the execution units executes a simulation by queuing theory based on the information generated by the information generation unit and the result value by the scheduling theory, and the other one of the execution units is generated by the information generation unit. The simulation system according to claim 1, wherein the simulation is executed by the scheduling theory based on the obtained information and the result value by the queuing theory. The judgment unit
The result calculated by the predetermined number of execution units is obtained on the condition that the result value calculated by the execution unit is equal to or more than the threshold value corresponding to the same execution unit or less than the threshold value corresponding to the same execution unit. The simulation system according to any one of claims 1 to 3, wherein it is determined that the determination conditions are satisfied when the individual conditions are satisfied. The judgment unit
In the same execution unit, the individual condition is that the newly calculated result value does not change with respect to the previously calculated result value, and a predetermined number of the calculation result values of the execution unit satisfy the individual conditions. The simulation system according to any one of claims 1 to 3, wherein it is determined that the determination condition is satisfied. The simulation system according to any one of claims 1 to 5, further comprising a search unit for identifying and notifying one of the transport devices having the greatest influence on the simulation result executed by the execution unit. Multiple execution units calculate information about the processing capacity of a transfer system equipped with multiple types of transfer devices.
It is a simulation method in which the optimization unit exchanges information with each of the plurality of execution units.
The plurality of said execution units
Run simulations based on different mathematical formulas to derive different result values
In the optimization section
Whether or not the result value that is the simulation result of any of the plurality of execution units is acquired and the acquired result value satisfies the judgment condition that is the individual condition corresponding to the execution unit from which the result value is acquired. Judgment department judges whether
When the determination unit determines that the determination condition is not satisfied, the execution instruction unit causes another or the same execution unit different from the execution unit to execute the simulation based on the result value.
A simulation method in which, when the judgment unit determines that the judgment conditions are satisfied, the output unit outputs the result value calculated by each execution unit as the processing capacity of the transport system.

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