SIMULATING THE OPERATION OF A TRANSPORTATION MACHINE

Abstract: The invention relates to a method and a system for simulating a transportation process when transporting goods from an initial location to a subsequent location. By simulating the transportation process it is possible to enter operational data related to the packing machine and subsequently view the packing process on a user interface of the simulating system. Accordingly the invention also relates to a user interface of the simulating system and to a user of the simulating system. The user interface comprises buttons for manipulating the transportation process and it is possible in the user interface to enter and to alter operational data in order to optimise the transportation process.

Description: SIMULATING THE OPERATION OF A TRANSPORTATION MACHINE The present invention relates to a method a method for entering, displaying and simulating an operation associated with a pallet in a transportation system, said method comprising the steps of inputting data associated with a transportation machine, the transportation machine being located in a system of co-ordinates, inputting pallet data associated with a pallet, the pallet being situated in a location with reference to coordinates in the system of co-ordinates, and inputting data associated with goods to be placed by the transportation machine on the pallet. The invention also relates to a system comprising a transportation machine for transporting goods from an initial location to a subsequent location, said locations being within a reaching distance of the transportation machine, and said subsequent location being a pallet onto which the goods are to be placed. Furthermore the invention relates to a user interface for a simulating system having a number of buttons for manipulating a simulation method and a use of a simulation system in a packing process. US 5,984,503 describes a method and an apparatus for displaying and entering information associated with structures in a machining system. The method and the apparatus comprise means for inputting data related to the different parts of the apparatus, also inputting data relates to a pallet with work pieces being placed in trays on a pallet, said work pieces being intended for being brought from the tray on the pallet to a fixture in the machining system. The operation of the apparatus comprises inputting the relevant data, and monitoring the machining process in order to possible adjust the data in relation to the machining process having been monitored. Also the monitoring of the process may be used to monitor the process automatically and afterwards being able to view how the process have been performed. This may be an advantage for finding reasons for possible defects in the work pieces having been machined. The method and the apparatus have the disadvantage of being able to locate any defects or other errors in the machining process only after the process have taken place. The defects may be faults in relation to the displacement of the work pieces from the trays on the pallet and to the working machine. However, the defects or other errors have already occurred when the monitoring reveals that they have occurred. Thus, it is not possible to completely avoid any defects or other errors, it is only possible to reduce the amount of defects by being able to closely monitor the process. It is the object of the present invention to be able to avoid defects or errors in a system where an item is to displaced from on position to another and where errors may occur due to wrong setting of the displacement parameters, due to the type, shape or weight of the goods or due to other conditions that may give rise to problems during displacement of the item. This object is obtained by a method of simulating placing the goods on the pallet by means of the transportation machine by simulating performing a transportation of the goods from an initial location of the goods, being away from the pallet and within a reaching distance of the transportation machine, to a subsequent location of the goods, being on the pallet and still within the reaching distance of the transportation machine, by simulating operating the transportation machine. By performing a simulated transportation of the goods from their initial location to their subsequent location, then it is possible to see whether the data entered into the system will result in a correct and desired transportation, or whether any alteration of any of the data is necessary for having the transportation performed without any faults. The method eliminates the need for having the faults occurring during the transportation process when being performed. The object of the invention is further obtained by a method comprising the further step of altering the initial operational parameters by inputting subsequent data than the initially data input of the transportation machine if the actual location is different to the desired location, and repeating altering the operational parameters, repeating simulating performing operation of the transportation machine by simulating transporting goods from an initial location to a subsequent location by means of the transportation machine, again checking the simulated actual subsequent location of the goods compared to a desired subsequent location, and further repeating said steps until the simulated actual location of the goods is the same as the desired location of the goods. This method makes it possible to alter the data easily and quickly if the transportation process is to be changed due the simulation of the transportation process showing the packing of goods on the pallet to be unsatisfactory. Also the method makes it possible to alter the operational data if the transportation process is to be changed due to other goods to be transported, due to use of another type of pallet or due to other conditions altering the transportation process. This is especially advantageously when the conditions of the transportation process often alter, as example several times during the day. In a preferred embodiment a simulation system is a packing system for packing of goods from a prior system, such as a production system, onto a pallet, the transportation machine being situated between the prior system and the pallet and said simulating system having means for entering data of the location of the prior system, data of the goods and data of the location of the pallet, and said system having means for displaying the data entered and having means for inputting altered data of the prior system of the goods and of the pallet, and said simulating system being capable of performing a simulated transportation of the goods from an initial location of the prior system and to a subsequent location on the pallet. If the transportation system is related to a packing system, then the products to be packed are fully manufactured and perhaps also packed in suitable packing such as sacks or boxes. The packing system is not for the actual enclosure of the products produced but is for the transportation from an initial location which can be the end of a prior system such as a production system to a subsequent location on a means for further transportation such as a pallet. The goods to be transported by the packing system may be items them- selves coming from as example a prior production system or may be items enclosed in containers such as boxes, sacks or the like thus coming from a prior but different packing system. The invention will be described further with reference to the enclosed drawings, where fig. 1 shows a user interface for entering and displaying initial data in a software program and related to a packing system according to the invention, fig. 2 shows a user interface for entering and displaying subsequent data in a software program and related to a packing system according to the invention fig. 3 shows a user interface displaying a layer of sacks located on a pallet with a subsequent placement of the sacks on the pallet fig. 4 shows a user interface displaying another layer of sacks located on a pallet with a different placement of the sacks on the pallet fig. 5 shows a user interface displaying a layer of sacks located on a pallet with and with an arrow indicating a direction of transportation of the sacks onto the pallet fig. 6 shows a user interface displaying a layer of sacks located on a pallet with and with a numbering indicating the order of transportation of the sacks to the pallet. Fig. 1 shows a user interface with windows for entering and displaying operational data of a transportation system, which in the embodiment shown is a packing system. The user interface is divided into two parts, a left part for entering and displaying operational parameters of the machine (Maskin parameter) and a right part for entering and displaying data related to the placing of a pallet stop and of a side push (Placering af pallestop og sideskub). In the left part of the user interface, the part for entering and displaying operational parameters for the machine, a first window is for entering and displaying the type of packing machine (Maskin type) which in the present example is a PANPAC 3. A second window is for entering and displaying the direction (Indløb) from which the pallet is entered into a reaching area of the packing machine as example the pallet entering from the right side (Palle ind fra højre) Operational data of the packing machine is set and displayed as default knowing the features and capabilities of the packing machine. In the example shown the packing machine is capable of moving a grab in incremental steps of 15,3 mm in both an X- direction of a system of co-ordinates and in a Y-direction of the system of co-ordinates. An offset value is entered as default knowing the type of packing machine. The offset value is a value set for the displacement between the centre of the goods, as example the sacks, and the grab of the packing machine. Also set and displayed as default is the direction of inlet of the goods, which in the present example is sacks, to the pallet knowing the type of packing machine. In the example shown the inlet is along the plane of the pallet, which is marked in the check-box. Another possibility being the inlet being vertical to the plane of the pallet, which in the case of the packing machine of the example is not possible why the check-box is not marked. Not set and displayed as default is the direction from which the piece of goods, i.e. the sack is transported to the pallet. In the present example it is possible to enter whether the sack is entered form the right side by marking the check box being the case in the present example. In the right part of the user interface, the part for entering and displaying placement of pallet stop (pallestop) and side push (sideskub), a first window is for entering and displaying the pallet stop, which in the present example is 600 mm. A second window is for entering and displaying the fixture point, which in the present example is 1660 mm. The distances are measured with relation to the system of co-ordinates having its place of origin in the bottom right corner of the pallet. The pallet stop is a stop defining the origo of the system of co-ordinates in the X-direction. The fixture point makes use of the side push in order to define the origo of the system of co-ordinates in the Y-direction. As ordinary possibilities of entering data in a Windows ® based program there is a button for saving the data entered (Gem) and a button for closing the user interface (Luk). Fig. 2 shows a user interface with windows for entering and displaying or rather for editing and displaying the so-called design which in a packing system means the pallet data and the location of the goods on the pallet. The user interface is divided into two parts, a left part for entering and displaying operational parameters of the design (Mønster) and a right part for only displaying an overview of the possible design (Mønstre oversigt). The left part of the user interface has a first window for entering the number of the design (Mønster nummer) from a list of possible designs shown in the right part of the user interface. A second window is for entering the type of pallet (Palle type) also to be chosen from a list in the right part of the user interface. In the present example the pallet chosen is an EUR pallet having a size of 800x1200 mm. A third and a fourth window are for entering the size of the sacks (Saekke størrelse). In the present example the sacks chosen are having a width (B) of 400 mm and a length (L) of 800 mm. A fifth window is for entering a displacement of the grab (Forskydning af grab +/-) in relation to the sack. In the present example the displacement is 20 mm. A sixth window is for entering and displaying data relating to the product (Produkt) in the sacks. In the present example the product are pellets having a size of approximately 4 mm in diameter and being provided with a bottom layer (med bundlag). The right part of the user interface is an overview of the designs possible to choose. In the present example a list of the number of the designs (Nr), a list of the type of pallet (Palle), a list of the type of sacks (Saek), a list of displacement of the grab (+/-) and a list of the type of products (Produkt) are displayed. These lists are used as possible choices to be made when entering data in the left part of the user interface. The different data to be chosen from the list may be chosen individually, i.e. it is possible to chose randomly and combine individually from the possible choices form the list. In an alternative embodiment the number of the design will determine the combination of the different data. As possibilities of entering data in a Windows ® based program there are a button for entering new data (Ny) and a button for selecting the data entered (Ok). Fig. 3 shows how sacks by simulation are placed in a layer on the pallet. The sacks and the pallet are only depicted in the user interface and are not physically present when simulating the placement of the sacks on the pallet. Thus, the placing of the sacks on the pallet is purely simulation. A first sack is initially placed on the pallet with the width of the sack aligned with a left-hand width of the pallet and the length of the sack aligned with a lower length of the pallet. A second sack is placed beside the first sack with the width of the sack also placed along the left-hand width of the pallet, and the length of the sack placed along an upper length of the pallet. A third sack is placed beside the first sack and the second sack with the width of the sack placed along the lengths of the pallet and the length of the sack placed along a right-hand width of the pallet. When all three sacks by simulation are placed in the layer on the pallet, then the sacks, in the present example, cover the entire pallet. After the sacks by simulation have been placed on the pallet, it is necessary to test whether the data that have been entered initially and relating to the sacks, the pallet and the location of the sacks, the packing machine and the pallet in relation to each other result in the sacks being located as intended on the pallet. It may occur that the sacks protrude outside the pallet, which must be corrected. Also, with other and smaller products than the sacks illustrated in the present example, it may occur that the location of goods on the pallet can be altered in order to have more goods placed in each layer on the pallet. Accordingly, the method of simulation locating goods on the pallet can be used to eliminate goods protruding outside the boundaries of the pallet and can also be used to optimise the location of the goods in order to have as many goods as possible placed in each layer of goods on the pallet. Fig. 4 is a user interface showing three layers placed on the same pallet. Layer 1 is the bottom layer placed directly on the pallet. Layer 2 is an intermediate layer placed upon the first layer and layer 3 is a top layer placed upon the second layer. Layer 3 only comprises two sacks. The user interface related to the pallet and the sacks also show the system of co-ordinates having its origo at the top right corner of the pallet. A tool bar is placed above the depiction of the different layers of sacks in relation to the pallet. The tool bar comprises a number of buttons which will be further described in the following with reference to the number that the button in question has when counted from the left side of the row of buttons. The first button is for opening an already existing file with operational data for a packing process. The second button is for saving the designs that has just been created by entering data in the first and the second user interface as described above. The third button is for printing of the designs that have been saved. The fourth button is for accepting the design and for downloading and storing the data of the design in a memory of the simulation system. The fifth button is for entering a further good, such as a further sack, in the layer being designed. The sixth button is for deleting an already placed good, such as an already placed sack, in the layer being designed. When deleting as example a sack, it is either possible to mark by use of a cursor the sack that has to be removed. Alternatively, if no sack is marked it will be the sack having the highest number (see fig. 6) that will be removed. The seventh to tenth button each depicts four arrows pointing in each their direction with a mutual angular displacement of 90°. The seventh button has an arrow that is pointing towards right coloured in another colour as the other arrows. The seventh button is pressed if the sack having been transported to the pallet is to be placed in the layer on the pallet as it is transported to the pallet. The eighth button has an arrow that is pointing downwards coloured in another colour as the other arrows. The eighth button is pressed if the sack having been transported to the pallet is to be turned 90 clockwise before being placed in the layer on the pallet. The ninth button has an arrow that is pointing towards left coloured in another colour as the other arrows. The ninth button is pressed if the sack having been transported to the pallet is to be turned 180 clockwise before being placed in the layer on the pallet. The tenth button has an arrow that is pointing upwards coloured in another colour as the other arrows. The tenth button is pressed if the sack having been transported to the pallet is to be turned 270 clockwise before being placed in the layer on the pallet. The eleventh button is for transferring the data entered to a means for operating the transportation machine such as a PLC. It will be possible to combine the fourth button (see above) and the eleventh button in one button. Such a button will function as a simultaneous downloading of the data to the memory of the simulation system and transferring of the data to the operating means such as a PLC. However, if a connection to the operating means such as the PLC is not established, then such a combined button will only download the data. The twelfth button is a scroll button for choosing among the programs having been saved in the system in order to use or modify the program. When a program is chosen, the design related to the data initially entered will be displayed on the screen. The thirteenth button is also for scroll button but for choosing among the different layers of goods saved as part of the entire program. The fourteenth button is for displaying a second user interface as showed in fig. 2. After the second user interface is displayed it is possible to enter data related to the pallet and to the goods such as sacks. The fifteenth button is for removing deleting an entire design. The sixteenth button is for entering a number of constant values of data that are to be used by the control system controlling the operation of the packing machine. The seventeenth button is for inserting a new layer in a design being created. The eighteenth button is for deleting an entire layer in a design being created. Fig. 5 shows the same as displayed in part of fig. 4, namely a layer of sacks placed on the pallet. The user interface displayed in fig. 5 comprises an arrow in the right part of the interface. This arrow is an indication of which direction that the sacks are transported by the packing machine to the pallet. This may be an advantage for the person simulating the packing taking into account the goods to be packed, i.e. their type, their size, their shape, their content and their weight. Fig. 6 also shows the same as displayed in part of fig. 4, namely a layer of sacks placed on the pallet. The user interface displayed in fig. 6 comprises a numbering on each of the sacks. The numbering indicates the sequence that the sacks are transported by the packing machine to the pallet. This may be an advantage for the person simulating the packing when deciding the packing sequence. In the example shown the packing sequence may seem obvious, but other goods such as goods having an odd shape compared to the square shape of the sacks may need to be rearranged after the first simulation of the packing in order to fill out the surface area of the pallet in a better way. Also, if some of the goods are to be deleted form the layer, the numbering of the goods is an easy way to select the goods to be deleted form the layer (se also description to fig. 4, sixth button). Once the simulation has been performed and the transportation results obtained by the simulation method using the simulation system has proven to be satisfactory, the operational data of the transportation machine is entered and stored in a means for operating the transportation machine in a virtual transportation process according to the operational data such as a PLC. It is possible to check whether the operational data of the transportation machine and the data relating to the goods and to the pallet in the PLC are the same as those entered in the simulation system. It is the operational data stored in the PLC, and not those data stored in the simulation system, that will govern the virtual operation of the transportation system. When it is assured that the data in the PLC corresponds to the data entered in the simulation system, then the data are stored in the simulation system for possible later use. In the description above, the method according to the invention and the corresponding system is described with reference to a specific transportation by means of a specific transportation system of specific goods. However, transportation may also be accomplished by other means of transportation than a packing machine with a grab. Thus it may be a belt conveyer, it may be chain conveyer or it may other machines using a grab. Also the goods may be other goods than sacks. Thus, the goods may be boxes, other containers of cardboard, of plastic, of metal of wood or made from other materials or it may be goods having a stable shape themselves and not needing to be packed in containers. Finally, the type of pallet may be any kind of pallet suitable for supporting goods, Thus the pallets may be trays, plastic pallets, wooden pallets as shown, or other types of pallets. The lay out of the user interface may be different than the lay out shown. The essential features of the invention, i.e. the possibility of entering and displaying data entered in the simulation system and afterwards being capable of displaying the subsequent simulated location of the goods on the pallet is the main needs to be fulfilled by the user interface. Thus, the design of the buttons, the design of the frame of the user interface and other specific details may be changed.

Claims: CLAIMS 1. A method for entering, displaying and simulating an operation associated with a pallet in a transportation system, said method comprising the steps of inputting data associated with a transportation machine, the transportation machine being located in relation to a system of co-ordinates, inputting pallet data associated with a pallet, the pallet being situated in a location with reference to co-ordinates in the system of co-ordinates, and inputting data associated with goods to be placed by the transportation machine on the pallet, and subsequently simulating placing the goods on the pallet by means of the transportation machine by simulating performing a transportation of the goods from an initial location of the goods, being away from the pallet and within a reaching distance of the transportation machine, to a subsequent location of the goods, being on the pallet and still within the reaching distance of the transportation machine, by simulating operating the transportation machine. 2. A method for checking the operational data of a transportation machine, said method comprising the steps of inputting initial operational data of a transportation machine, said operational data regulating the operation of the transportation machine, and simulating operation of the transportation machine by simulating transporting goods from an initial location to a subsequent location by means of the transportation machine and subsequently checking the simulated actual subsequent location of the goods compared to a desired subsequent location. 3. A method according to claim 2, said method comprising the further step of altering the initial operational parameters by inputting subsequent data than the initially data input of the transportation machine if the actual location is different to the desired location, and repeating altering the operational parameters, repeating simulating performing operation of the transportation machine by simulating transporting goods from an initial location to a subsequent location by means of the transportation machine, again checking the simulated actual subsequent location of the goods compared to a desired subsequent location, and further repeating said steps until the simulated actual location of the goods is the same as the desired location of the goods. 4. A method according to claim 2, said method comprising the further step of maintaining the initial operational parameters of the packing machine if the checking of the simulated actual subsequent location of the goods compared to a desired subsequent location reveals that the simulated actual location is the same as the desired location. 5. A simulating system for performing the method according to claims 1-4, said system comprising a transportation machine for transporting goods from an initial location to a subsequent location, said locations being within a reaching distance of the transportation machine, and said subsequent location being a pallet onto which the goods are to be placed, and said system comprising a simulation means for simulating the transportation of the goods from the initial location to the subsequent location, said simulation means being capable of simulating performing a transportation of the goods by the transportation machine. 6. A simulating system according to claim 5, said system being a packing system for packing of goods from a prior system, such as a production system, onto a pallet, the transportation machine being situated between the prior system and the pallet and said simulating system having means for entering data of the location of the prior system, data of the goods and data of the location of the pallet, and said system having means for displaying the data entered and having means for inputting altered data of the prior system of the goods and of the pallet, and said simulating system being capable of performing a simulated transportation of the goods from an initial location of the prior system and to a subsequent location on the pallet. 7. A simulating system according to claim 6, the means for entering data of the transportation machine at least comprising data on the location of the transportation machine, the means for entering data of the prior system at least comprises data of the final location of the goods in the prior system, said location being viewed upon as the initial location of the goods in relation to the transportation machine, and the means for entering data of the pallet at least comprising data on the location of the pallet. 8. A simulating system according to claim 6, the data of the transportation machine further comprising data on the reaching distance of the transportation machine, preferably at least the reaching distance towards the subsequent location of the goods, more preferably at least the reaching distance towards both the initial location of the goods and towards the subsequent location of the goods. 9. A simulating system according to claim 6, the data on the goods further comprising a number of the following data, the type of goods, the weight of the goods, the shape of the goods, the amount of goods, a possible difference in the type of goods, a possible difference in the weight of the goods, a possible difference in the shape of the goods and a possible difference in the amount of goods. 10. A simulating system according to claim 6, the data of the pallet further comprising data on the type of pallet, preferably also data on the length and the width of the pallet, more preferably also data on the height of the pallet. 11. A simulating system according to any of claims 5-10, wherein the location of the transporting machine, the initial location of the goods, the subsequent location of the goods and the location of the pallet all are related to a system of co-ordinates. 12. A simulating system according to claims 1-11 , wherein the goods are sacks having a non-stabile shape and containing materials not providing a stabile shape such as granules, filaments, a liquid or a paste. 13. A simulating system according to claims 1-12, wherein the goods are containers having a stabile shape such as card-board boxes, plastic boxes, wooden boxes or metal boxes. 14. A simulating system according to claims 1-13, wherein the goods are goods having a stabile shape themselves such as metallic products, plastic products or wooden products. 15. A user interface of a simulating system having a number of activating point such as buttons for manipulating a simulation method, said buttons comprising a button for adding a layer of goods to a packing process and a button for deleting a layer of goods to a packing process. 15. A user interface of a simulating system having a number of activating points such as buttons for manipulating a simulation method, said buttons comprising a button for adding a piece of goods in a layer of goods of a packing process and a button for deleting a piece of goods in a layer of goods of a packing process. 17. A user interface of a simulating system having a number of activation points such as buttons for manipulating a simulating method, said buttons comprising at least one button for turning a piece of goods in relation to an initial orientation of the piece of goods, preferably comprising a first button for turning the piece of goods 90° in relation to an initial orientation, a second button for turning the piece of goods 180° in relation to the initial orientation and a third button for turning the piece of goods 270° in relation to the initial orientation. 18. Use of a simulating system according to claims 5-14 for simulating a packing process by means of a packing machine when packing goods onto a pallet.

Inventors: HYLTOFT SOEREN, PEDERSEN CHRISTIAN, HYLTOFT, SOEREN, PEDERSEN, CHRISTIAN
Applicants: HYLTOFT SOEREN, IMPULS TECHNIC, PEDERSEN CHRISTIAN, HYLTOFT, SOEREN, PEDERSEN, CHRISTIAN
Application year: 2001
Main classification: G06F17
IPC codes: B65G61