AS/RS Real Time Simulation and Control Integrated System

Research
Xu Xusong, Xiong Hongbin
Department of Management science and Engineering
Economics and Management School of Wuhan University,
Wuhan, P.R. China, 430072
Abstract
Usually, AS/RS simulation and control system are separate. In our research, we have found
the way to build a real time AS/RS simulation and control integrated system based on the AS/RS control
system structure. The integrated system can be developed just using the AS/RS control system
programming language such as C++ 6.0.
In this paper, we focus on the integration of AS/RS simulation and control system, it describes
some of the key features and the more significant methods utilized in the building of simulation models
by using the virtual reality approach (involve main control module, ASRSVehicle model, conveyor
model ,trolley cart model, flow route define, object arrival/exit time model, etc).
An actual Case study about an automobile parts factory AS/RS project is presented in this paper,
compared the simulation results with the models built by flexsim 3.0 and actual operation data over 10
months, we found the real time AS/RS simulation and control integrated system is demonstrated feasible,
flexible and comprehensive. It provides a more flexible and less expensive method for AS/RS
simulation and implement , it help to evaluate and improve the design of AS/RS control system, perform
testing and commissioning in early design phase under a virtual reality environment.
Key words AS/RS, Simulation, Virtual Reality Technology, Control system Integration, Case study

1 Introduction
AS/RS (Automated Storage and Retrieval System) is an important key part of modern logistic
system, along with the consideration of limited space, high labor costs, requirements of flexibility,
expandability, quality, reliability, management control, AS/RS application increase rapidly throughout
the world in recent years, especially in China.
AS/RS system is very complex, it consists of lots of mechanical equipments, automation control
equipments, computer systems, and full testing on-site is difficult, expensive, time consuming. On the
other hand, AS/RS system cost huge, especially the initial investment cost. There are high risks
associated with implementation of such a complex costly system. Either the investor or the engineering
company needs a system could provide excellent overall system visibility, effective in communicating
concepts and design, reduce design and implementation time, significantly improve the design quality.
Simulation and emulation system has been proven to be an accurate predictor and valuable tool for
use in design and implement of AS/RS Project, it can provide an overall view that is often impossible in
the real situation. It is a powerful analysis tool to study the many design and operating alternatives.
We did the literature review to establish the justification and validity of our research. Usually,
AS/RS simulation and control system are separate. Many papers and literature are found about the real
time AS/RS simulation system and control system, but few about the integration. There are also many
simulation software such as Automod, Arena, Flexsim that can build very complex logistic simulation
system, However, they are mainly used for design verification, alternatives comparison, system
diagnosis, although Automod provides emulation with MCM(OPC), its still difficult and inefficient to
integrate with the real time control system. AS/RS control system is designed to run by connecting to the
devices such as ASRSVehicle, PLC, when finishing simulation, still need to rebuild the AS/RS control
system again, and the actual AS/RS control system control logic may be different from the prevenient
simulation systems. How to integrate the simulation and control system together is our objective.
While considering solutions to these problems, the practicality of developing an AS/RS simulation
and control integrated system was raised. Unlike most AS/RS simulation studies, we developed a new
approach to the design of AS/RS real time control system, simulation system, and their integration. The

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integrated system is built just base on the AS/RS control system structure by directly using the control
system programming language - C++ 6.0.
This paper is divided into five sections: Following the introduction, Section 2, basic concept of
AS/RS and simulation. Section 3, details about the design of the integrated AS/RS simulation and
control system. Section 4, Case study about an automobile parts factory AS/RS project. Section 5,
Conclusions and future applications and work.

2 Basic Concept of AS/RS and Simulation

2.1 AS/RS System Overview
According to the definition of The Material Handling Industry of America, AS/RS is a storage
system that uses fixed-path storage and a retrieval machine running on one or more rails between fixed
arrays of storage racks.
The AS/RS has following major components: storage rack, ASRSVehicle, transport devices
(conveyor, AGV, trolley cart), assistant devices(barcode scanner, weight scale), PLC control system,
computer integrated planning and control system. It is designed to do storing, retrieving, stock checking,
picking, container distribution and collection automatically,
2.2 AS/RS Computer Integrated Planning and Control Software System
Of all the systems, computer integrated planning and control system is the most important. It connect to
ERP/MRP and PLC control system, fetch working commands then dispatch ASRSVehicle, PLC system
(control conveyor system, trolley cart) and assistant devices(barcode scanner, weight scale)working. When
finishing store/retrieve, results will be transferred to ERP/MRP.
It is made up of following modules and sub-systems (each containing related subroutines):

Main control module

ASRSVehicle control module

PLC control module

Assistant devices control modules

System visual monitor and display module
By using timing and muti-thread technology, it connect to AS/RS database server, according to the
working commands, dispatch the relative devices working through the communication between IPC and
connected devices. The structure of AS/RS control system is illustrated in Figure 1.

Figure 1: The structure of AS/RS control system

2.3 AS/RS Simulation

Simulation is the imitation of a system, based on knowledge or assumptions about the behavior of
parts of that system, with the purpose of obtaining insight in the behavior of the whole system.
The following are general 5 steps for a logistic system simulation:

Prepare for simulation(problem description, information collection)

Define the objective system and its alternatives

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Build the computer simulation models

Run simulation alternative experiments

Analyze and verify the simulation outputs and alternatives
For an AS/RS system, it is designed to do storing/retrieving the right products in the right places at
the right time at the lowest cost. AS/RS Simulation system can help to reach the goal, with simulation,
numerous options were tested that are currently carried out either on-site or at test sites without
optimizing layouts and operating procedures and incurring large capital costs or disrupting operations.

3 Real time AS/RS Simulation and Control Integrated System Design

3.1 System design overview
We design the realtime AS/RS control and simulation integrated system by modifying the
prevenient main control module and adding the simulation modules. includes following modules :

M1:Main planning and control module(including the interface with AS/RS data process system)

M2:ASRSVehicle control module

M3:PLC control module

M4:Assistant devices control modules(barcode scanner, weight scale)

M5:System visual display and monitor module

M6:Virtual ASRSVehicle simulation control modules

M7:Virtual PLC simulation control modules

M8:Simulation parameters setup module

M9:Simulation data analysis module
All the above modules work together and are managed by the main planning and control module.
An interface between control module and simulation module is constructed, a simulation switch flag is
designed, when it switch to Y, the system works in simulation mode, the actual devices (ASRSVehicle,
PLC) stop working, the virtual devices (virtual ASRSVehicle, virtual PLC) will start to work. When the
flag switch to N, the system works in actual control system mode, the control system will connect to
actual devices, simulation modules stop working. Figure 2 shows the process flow and structure of the
new AS/RS control and simulation integrated system.

Figure 2

Process flow and structure of new AS/RS control and simulation integrated system.

There are many issues that could be addressed regarding the design of AS/RS integrated control
and simulation system, following are some of the important items.
3.2 Main Planning and Control Module Design
Its designed for control the AS/RS actual/virtual devices control and working order planning, by
using Virtual reality, database and timer technology, for every a time cycle, repeat the following works:

Actual/virtual devices control
The module keeps reading devices (PLC, weight scale, barcode scanner) status from the memory
array updated by the Actual /virtual devices threads/ timers. If condition is OK and exists command in
working task queue table, it will send commands to the actual/virtual devices.

ASRSVechiles dispatch
The module keeps reading ASRSVechile status code from the memory array updated by the Actual
/virtual ASRSVechile threads/ timers. If inspecting the ASRSVechiles idle and exists command in
working task queue table, It will send a command (store, retrieve, location to location, station to station)

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to ASRSVechile, the ASRSVechile will start to work. For the reasonable dispatch, the module is
designed to do storing/retrieving by turns: first do storing then do retrieving in next working cycle.

Update database tables
The module is designed to update the relative ASRS database table when devices status changed.

Devices error and exception handle
The module is designed to identify and record the devices exception occurrence and recovery in
AS/RS database during the system running, such as ASRSVechile encode error, motor overload error.
3.3 Actual Devices (ASRSVehicle, PLC) Control Modules Design
The modules only work in control system mode, by using thread and task queue technology,
through the communication of RS232/RS422 port between IPC and device, it keep scanning devices
status, fetching command from working queue table, sending commands to devices.
3.4 Simulation Model and System Design
AS/RS is a typical discrete system of queues, processors and event. In order to simply design the
simulation system, only the simulation of ASRSVehicle, PLC control system (roll conveyor, trolley cart)
are considered, other devices, such as weight scale, barcode scanner will be ignored. The key features
and main modules and methods utilized in the building of simulation system are summarized as below:
3.4.1Simulation clock, Simulation time/ real time rate factor, Simulation time pushing ruler
For the simulation timer pushing, a globe simulation clock(Cm) and the ASRSVechile and PLC
simulation clock (Cv ,Cp) are designed, they keep on working until simulation end.
In order to accelerate simulation, a time rate factor (time_rate) is designed, initially, its set as 1, if
it is set to 10, means 1 minute in simulation system is equal to 10 minutes in reality time.
Assuming the timer interval of clock Cm, Cv, Cp is Tm, Tv, Tp, so the corresponding minimum
time step is: Tm/time_rate, Tv/time_rate, Tp/time_rate. For every a time cycle, time will be increased in
a step, all the objects in AS/RS system is moving or waiting according to the corresponding clocks.
3.4.2 Mobile Object Movement Simulation Model
There are many mobile objects in AS/RS system, such as ASRSVehicle, trolley cart, roll conveyor,
transporter. In order to simulate the object movement, following basic theories are proposed:

2-Stage Movement Trip Theory
Usually, a mobile object could move in both horizontal and vertical direction, for either direction,
its movement trip can be divided into 2 stage: first, from the current position move to the first
destination position. Second, from the first destination position move to the last destination position.
Figure 3 shows the illustration of 2-stage travel trip theory for ASRSVehicle. This is example of a
storage procedure, in the first stage trip, the ASRSVehicle travel from the current position(Pc) to the
store-station(P1) to fetch the object, then move to the destination position (P2) to put the object into the
assigned rack no. Therefore, the complete 2-Stage Movement Trips are: PcP1, P1P2.

Figure 3 Illustration of 2-stage travel trip theory for ASRSVehicle.

Characteristic Velocity-Time Curve of AS/RS Mobile Object

In order to estimate the separate and total travel time for the 2-Stage trip mentioned above, a typical
velocity profiles are proposed as shown in Figure4. The area of triangle OAD represents the Critical
Distance(CD) of a mobile object. If the single trip distance is larger than CD, it will be considered as a
normal trip, like the trapezia OABC. If the distance is less than CD, just like the triangle OEF, it will be
regarded as a short trip, during the trip, the velocity can never reach the constant velocity.

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Figure 4 Characteristic velocity-time curve of AS/RS mobile object

At the assigned design velocity and acceleration, the critical distance (CD) can be calculated.
Therefore, once the distance of a single trip is confirmed, the type of trip (normal or short trip) can be
confirmed, and the maximum velocity and the total travel time can be calculated, then the movement
position Pi at time Ti during the trip can also be estimated.
For example, assuming the trip distance is S(m), velocity is V (m/s), acceleration and deceleration

V2 V2
+
,compared the S with CD
2 A 2B
S V
1 1
if it is a normal trip, the total travel time for this trip is : T= + ( + ).
V 2
A B
2

is A and B (m/s ), the critical distance can be obtained as CD=

3.4.3 Virtual ASRSVehicle Simulation Model

For the ASRSVehicle simulation model design, following elements are considered:

Dispatching Rule
Based on the AS/RS control system and timing technology, the dispatch of virtual ASRSvechile is
same as the actual ASRSvechile control system, it is arranged by the main planning and control module,
depends on the data in the working command queue table.

Movement Simulation: Travel distance, Travel time, Position
ASRSVehicle can work for different types such as: store in, retrieve, station to station, location to
location. During a working cycle trip, the actions can be separated into following steps:
Walk(Tw1)  Fork fetch goods(Tf1) Walk(Tw2)  Fork put goods(Tf2).
It moves simultaneously in both horizontal and vertical directions, moves along floor-mounted rails
parallel to the storage racks for horizontal trips, and along a mast for the vertical part of the trip.
According to the 2-stage trip movement theory and velocity-time curve mentioned above, by the
positions (Pc ,P1, P2) of the trip, the every single stage trip(trip 1, trip 2) distances in both horizontal
and vertical directions be calculated first, then at the assumed ASRSvechile velocity, acceleration, the
corresponding travel time (Tw1h, Tw1v), (Tw1h, Tw1v) in horizontal and vertical direction in trip 1,2
can be calculated too. Assuming the load/unload time and final travel time in trip 1, trip 2 is (Tf1,Tf2 ),
(Tw1,Tw2). The total time (Ti) consumed in the whole working period can be calculated as following:
Ti=Tw1+Tf1+Tw2+Tf2
Tw1=Max(Tw1h, Tw1v) , Tw2=Max(Tw2h, Tw2v)
During the travel trips, according to the 2-stage trip movement theory and velocity-time curve and
the simulation clock mentioned above, for every a cycle timer step i, the corresponding position (Pxi,
Pyi) of ASRSVehicles in both horizontal and vertical directions can be calculated too.

Simulation Statistical Data Analysis
Assuming total simulation time is TT, there are M ASRSVehicle s in the system, total N working
task need to be executed. When simulation finished, the statistical data and analysis for ASRSVehicle i
(i 1M) can be obtained as followes:
Work starting and finishing time queue : BT(i,1),ET(i,1) BT (i,j), ET (i,j)BT (i,N), ET (i,N)
Total travel_load time(s):
ST1(i,j)
Total travel_empty time(s):
ST2(i,j)
Total work time(s):
ST(i,j)= ST1(i,j)+ ST2(i,j)
Total idle time(s)
TT-ST(i,j)

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Utilization rate(%)
ST(i,j)/ TT 100
3.4.4 Virtual PLC Simulation Model
Similar to the actual PLC system, a simulation cycle timer is designed by using timing technology,
for every a cycle time, the designed PLC timer will keep scanning the status of virtual devices and
simulating the actions of actual devices.

Object Flow Path Definition
A database table is designed to record the definition of flow path. For usual conveyor stations, the
flow path can be defined by assign the next destination station of current one, but for the bidirectional
mobile devices such as trolley cart and lifter, both in/out flow path and ports must be defined.

Conveyor System Simulation Model
When an object enter a station of the AS/RS conveyor system, the relative clock and timer start
working, its next destination station and stand move time can be obtained from the flow path definition
table. For every a cycle time step, the waiting time increase, when the lapsed time is over the stand
time and next station is spare, the object will move to the next station, otherwise the object will stay till
its movement condition is ok. By this way, the object movement on conveyor system can be simulated.

Trolley Cart Simulation Model
The trolley carts simulation mode is very similar to ASRSVehicles, but the dispatching logic and
control must be redesigned like a real PLC systems: when a trolley cart is idle, there may be several
objects in different stations are waiting for it, a reasonable dispatching rule must be considered first,
once it is decided, similar to ASRSVehicle simulation mode, the corresponding travel path, distance,
total time consumed, positions at every time step can be calculated and simulated.

Simulation Statistical Data Analysis
Assuming simulation total time is TT, there are M PLC control devices in the AS/RS system, total
N work task need to be executed. When simulation finished, the object arrival/leave time queue for
device i (i 1M) can be obtained:
BT(i,1),ET(i,1) BT (i,j), ET (i,j)BT (i,N), ET (i,N)
By this queue, the following statistical data and analysis for station i can be obtained as followes:
Stay time queue
ET (i,1)-BT(i,1) ET (i,2)-BT(i,2) ET (i,N)-BT(i,N)
Idle time queue:
BT(i,2)- ET (i,1) BT(i,3)- ET (i,2)BT(i,N)- ET (i, N-1)
Total stay time queue (ET (i,j)-BT(i,j))
Total idle time queue (BT(i ,j)- ET (i,j-1))
Device idle rate(%)
(BT(i ,j)- ET (i,j-1))/ TT 100

4 Case Study
The integrated simulation and control system and models described above have been used in a
number of actual AS/RS applications. In this paper, a case study about an automobile parts factory
AS/RS project is presented to demonstrate the feasibility and validity of the integrated system.
4.1 Case Description
In this case, the AS/RS is designed for both use of sem-finished goods and finished goods. It is
built in a workshop of the factory. Not only for traditional warehouse use, the AS/RS is designed for the
packing sem-finished goods supply by directly connecting to the packing machines.
There are 2 ASRSVehicles, 2 PLC, 3 trolley carts in the system, the rack specification are: 4 row x
62 bay x 16 level=3968 cells, use tank as container, the max weight is 1000 kg. The system are designed
to work 8 hours/day, planning to finish incoming 200 tanks, outgoing 200 tanks, picking and stock
check 50 tanks, packing line supply 56 tanks. It requires the ASRSVehicle finish store/retrieve 70
tanks/hour. Figure 5 shows the AS/RS realtime control and simulation system layout display page:

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Figure 5

Example AS/RS realtime control and simulation system layout and visual display page

The main system work types and flow route of this AS/RS case are described as followes:

Storage: 3 route, station 1->cart 21->rack, station 1->cart 54->rack, station44->cart 54->rack.

Retrieve:3 route, rack->cart 21->station 8, rack->cart54->station 27, rack->cart54->station 48.

Packing supply: rack->cart54->station40->cart55->packing machines (56-62)-> station 29,64.

Picking, Stock check: rack -> cart 21-> station 9,10,19,20 working ->cart 21->rack.
The AS/RS simulation and control integrated system was built in Jul, 2005, the actual AS/RS was
installed and started running in Sep, 2005. Following are some of simulation experiments of the time.
4.2 Simulation Experiments and Results Analysis
4.2.1 Simulation Parameters Setup
In this case, the basic simulation experiment parameters are as followes:

Rack specification: 4 row x 62 bay x 16 level= 3968 cells, rack unit size: 865Wx925Dx875H.

ASRSVehicle: travel speed 2m/s, lift speed: 0.5m/s, acceleration: 0.3m/s , load time: 15s.
2
Trolley cart(21,54, 55): travel speed 0.8m/s, acceleration: 0.2 m/s , load/unload time: 8s.
Roll conveyor: travel speed 0.3m/s.

4.2.2 Simulation Experiments

ASRSVehicle Limit Output Test:
In order to measure the maximum capacity of ASRSVehicle, a simulation model with only one
ASRSVehicle and corresponding 2 racks is built, at the assumed devices(ASRSVehicle, conveyor, rack)
specification and parameters, by randomly assigning the store/retrieve rack no, after for about one
hours simulation running, simulation output data are collected and the results are shown in Table 1:
Table 1. ASRSVehicle limit output test results (1 hour)
Working type
In
Out
total
Utilization (%)
Only store in
45
45 99.99
Only retrieve out
41
41 99.99
Both In/out
28
28
56 89.00

Continuous Store/Retrieve Flow Route Time Test:

In this simulation experiment, for some continuous assigned working tasks, we could calculate the
times consumed on the ASRSVehicle, conveyor, trolley cart. Some of the results are shown in Table 2:

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Seq

Type

1.
2.
3.
4.
5.

In
Out
In
Out
In

Table2. Continuous s store/retrieve flow route time consumed test results

Time consumed(s)
Flow route
conveyor
Trolley cart
ASRSVehicle
1 -> 12 -> 21-> 0303606
42
16
76
0100108-> 32 -> 54 -> 27
38
18
60
24 -> 54 -> 31-> 0204407
42
27
72
0404407 -> 13 -> 21 -> 8
59
16
74
1 -> 16 -> 21-> 0203206
62
18
52

Total
134
116
141
149
132

Integrated Emulation Test:

In the AS/RS daily operation, storing, retrieving, supplying packing line, picking, stock checking
are dispatched by the main planning and control module, and can be done in the same time. In order to
simulate this situation and test the system performance (throughput, bottleneck, equipment utilization ),
about 100 records are prepared in working queue table for integrated experiment. After running for
about 1 hour, simulation finished. Table 3 shows some of the sum-up results.

Device

In

Table 3. Integrated emulation test sum-up results

Out
total
Stay time (s)
Min

Average

Max

ASRSVehicle1
26
29
55
19.77
37.19
48.88
ASRSVehicle2
24
26
50
26.19
38.50
47.87
Trolley cart21
43
43
10.08
15.18
20.52
Trolley cart54
68
68
12.98
21.90
33.27
Trolley cart55
14
14
17.69
33.09
43.17
Station 1(in)
15
15
60.00
96.87
393.69
Station 24(in)
15
15
65.98
161.61
462.90
Station 46(in)
15
15
68.64
175.39
482.14
Station 8(out)
14
14
34.04
103.38
125.12
Station 27(out)
14
14
50.00
95.00
135.00
Station 48(out)
13
13
51.37
139.89
242.34
Remark: the time interval for store, retrieve, pick, packing supply is 180s, 180s, 720s, 500s.

Utilization
(%)
96.30
93.21
49.88
81.91
33.75
96.25
87.47
91.68
86.61
61.66
34.22

4.2.2 Simulation Results Analysis

By the above simulation experiments and output data, following analysis conclusions are obtained:

The ASRSVehicles maximum output for store/retrieve is about 112 tanks/hour, this is also
the limit output of AS/RS. Compared with the system design requirement (70 tanks/hour),
only need the ASRSVehicles utilization over 63%, the design requirement will be met.

In order to test the limit output of the system, in the above integrated simulation experiment,
enough data were prepared for the system, the ASRSVehicles cost about 60 minutes finish
105 tanks in/out, including (store in, retrieve, delivery out, supply packing line, picking etc),
the results also verified the design validation. On the other hand, all the ASRSVehicles
utilization are over 90% (the usual suggested utilization is about 70%-80%). Compared with
conveyor and trolley cart systems utilization, the ASRSVehicle maybe the bottleneck for the
future system output improvement.

For the flexibility and convenience of connecting to workshops and the manufacture flow, the
AS/RS store in/out stations are arranged in both origin and opposite side of the rack. During
simulation, we found this layout design will reduce the efficiency of ASRSVehicle about 20%
than the usual mode because of the ASRSVehicles travel-empty time were increased.

If one ASRSVehicle have to handle several stations in the same time just like this case, the
dispatch for ASRSVehicle storage must be considered very carefully, otherwise it will keep
storing just on one side while the other sides object keep on waiting. By simulation, we found
the bug mentioned above in control system design and correct it.

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Compared with the simulation model built by Flexsim3.0, we found the two simulation results are
very similar. After the AS/RS system installed, about 10 months daily operation actual data are collected,
we do the comparison again, and also found the integrated simulation and control system is
demonstrated feasible, flexible and comprehensive.

5 Conclusions and Future Work

This paper presents the concept, modeling method of building AS/RS real time simulation and
control integrated system based on the AS/RS control System structure. By just using the AS/RS control
software system programming language, such as C++, Delphi, Vb, the integrated control and simulation
system share the same logic, can be developed more quickly, and is more easier to modify, much less
costly to run, easier to explain to the customers.
Several experiments and projects have been carried out for the design and simulation, testing of
new AS/RS, and the diagnosis of the existing AS/RS systems. All the results show that the above
integrated system is indeed feasible and provide many benefits.
As future study, many promising research directions have been identified and presented, mainly for
simulation modules. The system visual display mode will be changed form from 2D to 3D style. To
reduce the time drastically for simulation modeling, more stand components will be added into the
simulation module such as processor, combiner, separator, etc. We are also considering the possibility of
designing a simple visual assistant constructor for object flow path definition just by mouse drag. Other
improvement and modification such as devices MTBF, MTTR, object arrival/exit time distribution,
data statistical analysis will be considered in the next version.

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