Automation · Robotics · Warehouse simulation

Warehouse 1 · SMD 1 → LSW 1
17-lane sorter, 6 ABB palletizing robots.

A working model of the case handling and robotic palletizing in Warehouse 1 (22 × 21 m, 460 m²), laid out from the floor plan. Cigarette master cases from SMD 1 cross the sky bridge, spiral down to the floor, are scanned and sorted by SKU onto 17 lanes, and six ABB IRB 660 robots build single-SKU pallets. Every case, pallet and robot move is simulated; product and pallet data can be changed below.

Time speed

Random failures Machine labels Lane labels SMD 1 producing

Property of
PT. Autoen Industri Teknologi

Drag to orbit · right-click/Shift+drag to pan · scroll to zoom · click a machine for details

Running (green light) Idle, waiting for cases (amber) Blocked, downstream full (amber) Down (flashing red) Waiting for empty pallets Coloured band on each case = SKU · pallet sign colour = SKU of that position

Simulation time

00:00:00

real time

Intake efficiency

—

SMD 1 output taken away

Inflow from SMD 1

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average of the last 5 minutes

Cases palletized

0 t

Pallets completed

—

Exception cases

—

Machine panel

Change setpoints with − / + · actual speed = average of the last 60 seconds ·

Machine	Setpoint	Actual speed	IN	OUT	Status	Running

Selected machine

Palletizer

Speed

MTBF (min)

MTTR (min)

Cases per minute

━ inflow from SMD 1 · ┅ placed on pallets · last 60 minutes, in cases per hour

Sorter lanes & pallets

The WCS gives each SKU its own lane and pallet · click a row to see the robot

Lane	Pallet pos.	SKU	Status	On lane	Pallet	Done

Product & flow setup

Change the data, check the preview, then apply

All values below are placeholders until the real data arrive. The pallet pattern, cases per pallet, lane buffers and the robot reach check are recalculated from these numbers.

Current configuration (JSON)

How the model works

Layout from the Warehouse 1 floor plan (22 × 21 m). The six robot circles on the plan are about 6.2 m across, which matches the 3.15 m reach of the ABB IRB 660-180/3.15, so that model is used. Robots stand at x 3.45 m and 18.55 m, cells centred 4.8 / 11.0 / 17.2 m from the north wall.
Route from the product flow diagram: SMD 1 → CBC conveyor → sky bridge → WH-1 entry → barcode scan & sorter → robotic palletizing. Assumed: the sky bridge enters through the east wall at 4.5 m and a 3-turn spiral (Ø 2 m) brings cases down to the 0.8 m working level.
Sorting: roller conveyor along the blue-purple line on the plan with 9 pop-up wheel divert modules (one per lane pair, both directions), 0.9 m/s, 300 mm minimum gap made by the metering belt. The divert path is a conveyor of its own: 1.0 m radius curve to 30°, 0.7 m spur, 0.6 m radius bend into the lane, all at sorter speed. Lanes are 0.4 m/s zero-pressure roller lanes.
Each robot reaches 3 pick points: R1–R5 serve 3 sorter outlets each (15). R6 serves outlets 16–17 and the exception lane at the end of the sorter, so all 17 outlets and the exception path are covered.
WCS logic (assumed): a lane is given to an SKU when its first case is scanned and released when the SKU stops and the lane is empty; its part pallet is then closed. A fast-running SKU gets a second lane if at least two lanes are free. No-reads and SKUs without a free lane go to the exception lane and onto a mixed pallet.

Placeholder product: master case 560 × 290 × 450 mm, 12.5 kg, 500 packs; pallet 1,200 × 1,000 mm, 3 layers of 6 = 18 cases, about 1.5 m high. SMD 1 sends 720 cases/hour with 14 of 24 SKUs running at once, a SKU change every 12 minutes on average and 0.5% no-reads.
Robot motion: J1–J3 130°/s, J6 300°/s, linear moves 3 m/s, no zone blending, so cycle times are on the safe side. All moves cross a fixed safe plane above a full pallet, because the shuttle may pass behind the robot. Cases are lowered 40 mm clear of the stack and slid into place; the lane stops while the robot lifts a case off it.
Pallet flow: 3 build positions and 1 empty-pallet stack stand behind each robot on 0.3 m high roller conveyors. A full pallet rolls onto a rail-guided shuttle along the wall (1.0 m/s), which takes it to a pickup station in the 1.4 m south aisle; a forklift (1.6 m/s) takes it out through the dock door and brings back stacks of 10 empty pallets for the shuttle to deliver.
Checked in Node over 40 minutes: no two cases overlap (box collision test every 0.1 s), no two pallets overlap on conveyors, shuttles or the forklift, loads carried by a robot never pass through a pallet or the stack, no conveyor overlaps another conveyor, pallet position or robot base, and every robot work point is reachable (IK→FK error < 1 mm). MTBF and MTTR values are examples.