Automation · Robotics · Warehouse simulation

Warehouse 1 · SMD 1 → LSW 1
16-lane sorter, 4 ABB palletizing robots.

A working model of the case handling and robotic palletizing in Warehouse 1 (22 × 21 m, 460 m²), laid out from the floor plan. Cigarette master cases from SMD 1 cross the sky bridge along the north and west walls, are scanned on the bridge, spiral down to the floor and are sorted by SKU onto 16 lanes across the middle of the hall; four ABB IRB 660 robots (two north, two south) build single-SKU pallets, and AMRs carry them to the two transit rooms on the east side. Every case, pallet, robot, AMR and forklift move is simulated; product and pallet data can be changed below.

Time speed

Random failures Machine labels Lane labels SMD 1 producing

Property of
PT. Autoen Industri Teknologi

Drag to orbit · right-click/Shift+drag to pan · scroll to zoom · click a machine for details

Running (green light) Idle, waiting for cases (amber) Blocked, downstream full (amber) Down (flashing red) Waiting for empty pallets Coloured band on each case = SKU · pallet sign colour = SKU of that position

Simulation time

00:00:00

real time

Intake efficiency

—

SMD 1 output taken away

Inflow from SMD 1

—

average of the last 5 minutes

Cases palletized

0 t

Pallets completed

—

Exception cases

—

Machine panel

Change setpoints with − / + · actual speed = average of the last 60 seconds ·

Machine	Setpoint	Actual speed	IN	OUT	Status	Running

Selected machine

Palletizer

Speed

MTBF (min)

MTTR (min)

Cases per minute

━ inflow from SMD 1 · ┅ placed on pallets · last 60 minutes, in cases per hour

Sorter lanes & pallets

The WCS gives each SKU its own lane and pallet · click a row to see the robot

Lane	Pallet pos.	SKU	Status	On lane	Pallet	Done

Product & flow setup

Change the data, check the preview, then apply

All values below are placeholders until the real data arrive. The pallet pattern, cases per pallet, lane buffers and the robot reach check are recalculated from these numbers.

Current configuration (JSON)

How the model works

Layout (revision 7) on the Warehouse 1 floor plan (22 × 21 m) with the two transit rooms on the east side (x 19–22 m). The sky bridge still enters at the north-east corner at 4.5 m, runs along the north wall and down the west wall; the scan tunnel sits on the bridge and a 3-turn spiral (Ø 2 m) in the middle of the west wall brings cases down to the 0.8 m level, straight into the sorter.
Sorting: roller conveyor across the middle of the hall (west → east, z = 10.5 m) with 8 pop-up wheel divert modules (one per lane pair, both directions), 0.9 m/s, 300 mm minimum gap made by the metering bend. The divert path is a conveyor of its own: 1.0 m radius curve to 30°, 0.7 m spur, 0.6 m radius bend into the lane, all at sorter speed. Lanes are 0.4 m/s zero-pressure roller lanes holding 5 cases. The sorter ends in a 2-case no-read pocket before the transit rooms; a sensor calls an operator who removes the case by hand (45 s assumed).
Four ABB IRB 660-180/3.15 robots at x 6.3 / 14.15 m, rows z 5.0 m (R1, R2, pallets to the north) and 16.0 m (R3, R4, pallets to the south). Each reaches 4 pick points 1.85 m in front of it (lanes at ±0.6 and ±1.8 m), so all 16 outlets are covered.
WCS logic (assumed): a lane is given to an SKU when its first case is scanned and released when the SKU stops and the lane is empty; its part pallet is then closed. A fast-running SKU gets a second lane if at least two lanes are free (the two spare lanes start as second lanes of the two fastest SKUs), earlier when its pallet position is waiting for an empty pallet. When a SKU pauses, its part-built pallet stays on the position and the lane is held for that SKU; it is only closed early when a new SKU needs the lane, so the AMR normally collects complete pallets only. No-reads, SKUs without a free lane and cases that find their lane full run on to the no-read pocket.

Placeholder product: master case 560 × 290 × 450 mm, 12.5 kg, 500 packs; pallet 1,200 × 1,000 mm, 3 layers of 6 = 18 cases, about 1.5 m high. SMD 1 sends 720 cases/hour with 14 of 24 SKUs running at once, a SKU change every 12 minutes on average and 0.5% no-reads.
Robot motion: J1–J3 130°/s, J6 300°/s, linear moves 3 m/s, no zone blending, so cycle times are on the safe side. All moves cross a fixed safe plane 2.45 m above the floor (above a full pallet plus a carried case), where the IRB 660 envelope only reaches about 2.64 m; that is why the build positions sit within 2.6 m of the robot (P1/P2 ±1.55 m beside it, P3/P4 ±1.8 m and 1.25 m behind) and the pick points at 2.58 m. Cases are lowered 40 mm clear of the stack and slid into place; the lane stops while the robot lifts a case off it.
Pallet flow: 4 build positions on 0.3 m high roller conveyors around each robot, with a 29° sector directly behind the robot kept clear. A full pallet is rolled away from the robot onto its AMR station (1.05 m sideways for P1/P2, 1.3 m back for P3/P4) and the robot carries on with the other three. Two ABB Flexley Mover P603 AMRs (1,285 × 835 × 300 mm, lifting table 160 mm, 1,500 kg, 1.8 m/s assumed with light pallets, turning on the spot), one per row, drive along the north/south wall corridors and the cross aisles, dock 3.9 m or more from every robot, drive under the station stand (roller rails at the edges, 0.95 m gap), lift the full pallet and reverse out, take it to the transit room stand through the wall opening and bring an empty pallet back from the pallet dispenser next to it; the station conveyor rolls it into the build position. A forklift (1.6 m/s) works only in the transit rooms and the east yard: it takes full pallets to the trucks and loads stacks of 10 empty pallets into the dispensers. Pallet conveyors and stands are 0.33 m high so the 0.30 m AMR passes underneath. Safety fences: every robot cell is fenced; the fence lines (1.75 m / 19.25 m at the wall corridors, 9.0 m / 12.15 m at the sorter, 1.5 m, 17.25 m and the cross aisle at 9.4–11.05 m) are checked against every AMR path with a 1.2 m pallet on board (1.6 m light-curtain openings, 1.0 m openings for the lanes), the turning circles, all stands and conveyors and the robot reach; the north cell is notched around the spiral.
Checked in Node over 60 minutes: no two cases overlap (box collision test every 0.1 s), no two pallets overlap on conveyors, AMRs, dispensers or the forklift, loads carried by a robot never pass through a pallet, no conveyor overlaps another conveyor, pallet position, robot base, dock or wall, every AMR dock and corridor junction has a clear turning circle, and every robot work point is reachable (IK→FK error < 1 mm). MTBF and MTTR values are examples.