Industrial vehicles and conveyor systems, such as stacker cranes, hoists, bridge cranes / overhead cranes, shuttles, material lifts or elevators, incur operating costs on a regular basis. To keep those expenses at a minimum and to enable plant operators to leverage the benefits of potential savings, PSI Technics developed the FLP6000EOS Energy Optimizing Software for the ARATEC Positioning Solution System.
FLP6000EOS was specifically developed for systems with multiple axes and is available as an optional add-on for the ARATEC Positioning Solution System.
The ARATEC Positioning Solution System provides time-optimized controls that enable logistic facilities to operate at maximum capacity. The modular FLP6000EOS add-on enables you to precisely reduce operating expenses to achieve optimum positioning performance. Increased operating expenses incur due to high energy costs – the savings potential with FLP6000EOS software is substantial.
Mercedes Benz Factory, Düsseldorf, Germany:
"Prior to modernization spare parts for the old system were increasingly difficult to obtain and warehouse productivity no longer met the Daimler AG's high standards. Thanks to PSI Technics' ARATEC Positioning Solution System warehouse positioning operations are faster and more reliable than ever. Another important modernization requirement was to guarantee the availability of the existing warehouse until at least 2018 – an additional aspect in favor of PSI Technics' ARATEC Positioning Solution System. The system seamlessly integrates into the existing warehouse infrastructure. In addition, the FLP6000EOS software reduces facility wear and benefits the energy budget. The solution ensured that Daimler AG's clearly formulated initial requirements for the modernization process were more than met."
The modular FLP6000EOS add-on considerably increases positioning efficiency, saves energy and reduces maintenance costs to increase the life-span of industrial facilities and ensure a fast return on investment.
The energy consumption of a conventional motor drive (IEC energy class EFF2) is approximately proportional to the maximum travel speed (vmax), which in turn determines the energy required for acceleration. Even when using a brake feedback loop, this proportional interdependence will be reduced, but in principle still persists. Energy consumption increases accordingly, depending on vmax. This is where the intelligent FLP6000EOS Energy Optimizing Software comes into play. It determines, on a case-by-case basis, whether maximum velocity is required to achieve optimum performance. If maximum velocity is not required, it automatically adjusts the speed - significantly reducing facility wear.
Axis Speed Optimization
A stacker crane with 2 axes used to be positioned conventionally by two separately controlled drives (e.g. with the Trimble ICS5000). Positioning took place using predefined static speed values. Now, PSI Technics' FLP6000EOS automatically controls multiple axes in dynamic mode and adjusts the vehicle's speed to the match the actual positioning time. The FLP6000EOS precisely determines the positioning time based on the automatically calculated motion path.
Diagram 1: Positioning a vehicle with two axes
The system receives a travel command (X 20 m, Y 10 m). With a conventional travel profile (green line), both axes are positioned at the target location with maximum speed. The vehicle's y axis has a shorter travel distance and reaches the target position faster. Maximum velocity, however, won’t render any benefits, since the x axis has to travel a longer way and is going to reach the target destination later.
Using the optimized travel profile (blue line), the speed of the vehicle's y axis is adjusted to match the speed of the x axis. This way, both axes reach the target position at the same time.
Diagram 2: Conventional travel profile v(t) for both axes
Both axes travel at maximum speed, but due to the different travel distances, they reach the destination at different times.
Diagram 3: Optimized travel profile v(t) for both axes
After the FLP6000EOS calculates and optimizes the travel profile, the y axis' final speed can be reduced. The speed remains significantly below vmax and the y and x axes arrive at the target position simultaneously.
Optimization of Throughput Time
Necessity, not maximum velocity, is the decisive factor for determining positioning speed. Positioning time is determined by the throughput time of the entire warehouse. Against this backdrop, maximum velocity can amount to costly "luxury", when the warehouse throughput time is subject to its own cycles and can’t benefit from this "head start". A more moderate approach still ensures an adequate velocity and is considerably more efficient from a savings point of view.
By analyzing either the already traveled distances or by calculating the average warehouse throughput time supplied by the warehouse process computer, the FLP6000EOS software achieves maximum efficiency. Users can enter an expected capacity utilization in the FLP6000EOS software. The software then uses this value as a basis for matching the travel speed to the actual warehouse throughput conditions.
ARATEC® TPCC® - Registered in U.S. Patent and Trademark Office
Links>Application Reports >Customer Feedback >Videos >Stacker Cranes >Crane Systems / Bridge Cranes >ASRS Vehicles / Automated Industrial Vehicles and Conveyor Systems >ARATEC & Positioning Modules >Factory Automation & Process Optimization >Modernization / Retrofitting >Virtual Modeling / Finite Element Method (FEM) >Performance Analyses >MA6000MC Motion Analysis Kit >FLP6000AOC Advanced Oscillation Control >FLP6000ASC Skew Control Software >Tandem Operation
Downloads>Consulting and Analyses Product Flyer (PDF) >We are going to show you what your logistics system can do – Presentation for stacker crane applications (PDF) >We are going to show you what your logistics system can do – Presentation for bridge crane applications (PDF) >The ARATEC Positioning Solution System Product Brochure - Modernizations / New Installations (PDF) >The ARATEC Positioning Solution System Product Brochure - Replacement for Trimble / Spectra Precision / Geotronics (PDF) >ARATEC ATC - Advanced Track Control System - Data Sheet (PDF) >Optimized Warehouse Logistics Product Flyer (PDF) >FLP6000AOC Advanced Oscillation Control & New Machine Model Identification Data Sheet (PDF) >The ARATEC Positioning Solution System vs. ICS5000 Comparison Sheet (PDF) >The ARATEC Positioning Solution System vs. PLC Comparison Sheet (PDF) >FLP6000ASC Advanced Skew Control Software Data Flyer (PDF) >Tandem Operation Data Sheet (PDF) >FLP6000EOS Energy Optimizing Software Data Sheet (PDF) >FLP6000MA Motion Analyzing Software Data Sheet (PDF) >ARATEC Dashboard Data Sheet (PDF) >PSI Technics Reflector Foils Data Sheet (PDF)
PSI Technics is known for its expertise in industrial image processing and automation technology. Take advantage of our extensive analysis and optimization know-how for automated warehouse and production processes to increase the life-span of your facility.
We assist you every step of the way to help you find an optimization solution that is right for you or develop custom industry and application-specific applications based on digital imaging processing systems to increase the quality and productivity of your products and processes.
...designed for the continuous monitoring and visual quality control of production processes.
PSI Technics offers easy-to-use, application-specific digital image processing solutions that are designed for the continuous monitoring and quality control of production processes. Nearly all monitoring and measuring tasks can be automated by means of industrial image processing. Show movie
We invite you to experience a completely new type of control technology – in an entertaining short story. A clear and straightforward presentation will show you why the ARATEC is the best positioning solution on the market: For STACKER CRANE applicationsFor BRIDGE CRANE applications
PSI Technics' ARATEC Positioning Solution System is an innovative and advanced solution for industrial positioning applications. Show movie
The ARATEC's FLP6000AOC software reduces mast oscillations – even of highly dynamic stacker cranes – to a minimum. The test setup shows that the ARATEC Positioning Solution System with enabled FLP6000AOC compensates for mast oscillations in near-real time, even when the oscillations are caused by external disturbances.
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