Material flow computer
A material flow computer (ger .: material flow controller, MFC) is a software to control the data and information flows in automated systems and high-bay warehouses . It is also sometimes referred to as a data concentrator (DKZ) .
Different machines and components of automatic system parts such as conveyor technology , transfer cars and storage and retrieval machines can be controlled by material flow computer software. A visualization gives the operator an overview of the current material flow in the plant and provides the basis for fault diagnosis and troubleshooting. Modern, independent material flow computers also offer extensive diagnostic functions and support the operator in troubleshooting.
control
The material flow computer (MFR) is software that takes over the central control in automatic warehouses and complex production plants. It enables communication between the connected components. In the case of an automatic warehouse, these are among others
- Storage and retrieval machines that store the goods on the shelves and remove them again when required
- Conveyor technology that transports pallets or containers with goods through the warehouse
- Transfer cars, which also transport pallets with goods through the warehouse
- Lift systems that connect conveyor technology on several levels
- Sorters that sort the goods according to certain specifications
- Machines such as coverers or destackers for containers, test systems for pallets and production machines
- a higher-level merchandise management system (software) to which changes in inventory must be reported
Difficult conditions prevail when the individual components come from different manufacturers or if some older hardware with modern storage and conveyor technology is to be used in the same warehouse. In this case, a material flow computer with configurable interfaces is necessary in order to still be able to control the automatic warehouse centrally.
Differentiation from the data concentrator (DKZ / DAKO)
In everyday life, the terms material flow computer and data concentrator are often used synonymously. Strictly speaking, a data concentrator in the original sense describes a variant of the material flow computer, as it was used by many storage technology manufacturers to implement their systems until around 1998.
The data concentrator software was installed on the control level above the various stacker cranes and provided an interface for the entire system for the upstream warehouse management system. The warehouse management system could send normal transports to the data concentrator and this controlled the individual system components accordingly. Often these systems were mapped within a programmable logic controller (PLC) such as Simatic S5, Simatic S7, Siemens or MMC 216 and then referred to as the head controller of the system.
The data concentrator is connected to the individual system components in different ways, depending on the manufacturer of the system. A hierarchical topology exists when the systems communicate with each other exclusively via data interfaces . However, extensive digital connections were often installed to the individual components, which make modernizing these systems relatively expensive. Conveyor technology control and data concentrator form a unit and are not separated from one another by defined interfaces.
Today a DKZ usually only controls one type of component, i.e. only storage and retrieval machines or only conveyor technology . In other words, the DKZ is a kind of permanently programmed communication center with few control options . In addition, the DKZ is used by some manufacturers as a kind of black box. For the user, this has the disadvantage that, for example, in the event of malfunctions or planned warehouse expansions, he cannot access the software himself. For this he is dependent on the manufacturer.
Control concepts
A material flow computer (MFR) receives transport orders from a higher-level system. These include, for example , inventory management systems , warehouse management systems and production planning systems. The transport orders define that a specific loading device should be transported from a source to a destination. There are basically four different types of transport orders in the automated warehouse:
- Outsourcing: The source is a storage compartment and the destination is a location of the conveyor technology
- Storage: The source is a place of the conveyor technology and the destination is a storage compartment
- Transport: The source and destination are places in the conveyor system
- Relocation: Source and destination are storage bins
The MFR divides these transport orders into sub-orders that are understandable for the individual system components. In this way, he ensures that the right system components are addressed at the right time and that the requested loading equipment arrives at its destination quickly and without disruption.
In order to achieve this, MFR essentially work with three different control concepts:
- Control of the conveyor technology via transport orders from a defined source to a defined destination
- Control of the conveyor technology from reporting point to reporting point
- Place-by-place control of the conveyor technology with booking of the loading device data in the MFR
Depending on the material flow computer, one or more of these concepts are available. When modernizing automatic warehouses , the concept is in many cases required by the existing programming of the conveyor technology controls. Only the latest generation of material flow computers can generally use all three concepts as required. This makes the operator of the plant or the warehouse flexible for later extensions and changes. He is not necessarily dependent on the components of his previous manufacturer, but can choose the components that best meet his requirements.
More functions
Modern material flow computers usually offer additional functions beyond the control of storage and conveyor technology. These include:
- Strategies and route calculation for optimal material flow, preventing traffic jams and avoiding disturbed areas
- Support in troubleshooting and troubleshooting
- Visualization of the entire material flow
- Measurement of performance data to optimize the material flow
- Logging of fault data
- Emergency strategies
See also
Individual evidence
- ↑ Article Midrange Magazin ( Memento of the original from April 27, 2015 in the Internet Archive ) Info: The archive link was automatically inserted and not yet checked. Please check the original and archive link according to the instructions and then remove this notice.
- ↑ Example of a manufacturer-independent material flow computer
- ↑ Portal Wir automatisierer ( page no longer available , search in web archives ) Info: The link was automatically marked as defective. Please check the link according to the instructions and then remove this notice.
