f+h Intralogistics 2/2016 (EN)

f+h Intralogistics 2/2016 (EN)1

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6 WORLDWIDE NEWS f+h Intralogistics 2/2016

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13 part of the modernization project, whereby the energy costs could be significantly reduced. Open heart surgery Before calling for tenders for the retrofit project, the automation specialist, Heitec, based in Erlangen, Germany, analyzed the modernization requirements and created a performance specification that included all of the key points and was discussed with all of the parties involved, such as the managers, operators and maintenance technicians. During this process, it was determined that the design of the operating functions on the control panels should not be changed significantly thus making it easier for the system operators to switch to the new system. The safety technology also needed to be updated in accordance with the latest state of the art. At the same time, the storage and retrieval operations (Image 01) could not be affected during the conversion due to ongoing production. To reduce project risks, Heitec developed the actual commissioning concept on a virtual model. The procedure was implemented as follows: To complete a retrofit, the specialists analyze the system on site, record the characteristics, generate a sketch of the system geometry and use this to create a virtual model on the computer (Image 02). The control software is tested and optimized on these models and placed into virtual operation before each of the retrofitting stages. The models provide significant functional data about a high-bay warehouse in real time so that the new control software 01 Storage and retrieval operations continue without any interruptions despite the ongoing retrofit work can be tested without blocking the real system. The commissioner uses the computer to execute exactly what he needs to do when commissioning the actual machine. With the help of the concept, the old and new system could be operated in parallel and the retrofitting work could be completed in stages. The new drive systems and control units for the racking storage and retrieval vehicles were preassembled and installed on mounting plates to ensure they could be exchanged swiftly. During the retrofitting phase, the old central control system was coupled via a corresponding interface with the new control unit so that all of the old and new functionalities were guaranteed while the retrofit was being implemented. The central control system, that coordinates the storage and retrieval operations in all of the lanes, was only replaced once all of the racking storage and retrieval vehicles had been retrofitted. 02 An animated model on the computer illustrates the functional data of the high-bay warehouse f+h Intralogistics 2/2016

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31 Supplement for international Supply Chain Management

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