Automation of carousel storage systems
Our Competences in this Project
CODESYS Control
Python
Node-RED
Docker Container
SALZ Components
Description of the Use Case
A network of carousel storage systems is a specialized approach for the efficient storage and handling of roll-based products, such as pipes or carpets. These systems advantage from carousel shelves to ensure optimal space utilization and easy accessibility for such items. All storage processes can handle items managed by batch or serial numbers. This is ensured through a connection to a higher-level ERP system. This connection enables the communication and exchange of relevant process data that is important for managing items.
To optimize storage and inventory management, our customer chose to integrate advanced control and automation technology from SALZ Automation.
The automation of the carousel storage systems was implemented based on the SALZ automation system. Docker containers were used for various software components, including Codesys for control, Python for communication with the ERP system, and Node-RED for visual process control and monitoring. The solution was complemented by components from SALZ Automation, such as remote I/Os, safety modules, industrial relays, and panel PCs.
Performance Requirements
Product data and batches for pick orders at the shelf are provided in real-time to optimize integration and automation.
Requirement
The requirement was to use a Docker container with Python to communicate with the SAP® system.
Networking of the various systems with high-speed data transmission required for real-time operations and process monitoring.
Requirement
The requirement was to network the various systems, including the control units, remote I/O stations, and web panels.
Creation of flows for the integration and control of the various systems and components.
Requirement
The requirement was to use a Node-RED container for visual programming and process monitoring.
Individual Steps of the Project
1. System architecture and components
SALZ automation system as a basic platform
The SALZ automation system provides the central control and monitoring platform. The SALZ Automation Controller AMAX-80C controls the hardware of the carousel system, communicates with the Modus TCP remote I/O islands and implements the logic programmed in Codesys.
Docker containers for more flexibility, isolation and simple administration
Docker containers are used for various software components, including Codesys for control, Python for communication with the ERP system and Node-RED for visual process control and monitoring. The use of containers facilitates the management and scaling of the software, as each component is operated in an isolated environment.
- Python container for SAP® integration and data processing: A Docker container with Python scripts handles communication with SAP® system to retrieve product data and batches for withdrawal orders. This reduces the need for additional PCs or interfaces. Python scripts process the data and communicate directly with the AMAX controller to transmit the required control commands.
- Node-RED container for visual programming: Node-RED is used for visual programming and process monitoring. It enables the creation of flows to integrate and control the various systems and components.
2. Communication and data transmission
Remote I/O islands for decentralised data acquisition via Modbus TCP
Sensors and actuators are recorded via remote I/O islands that are connected to the control system via Modbus TCP. This enables decentralised data acquisition and transmission. The Modbus TCP protocol ensures reliable and fast communication between the remote I/O islands and the control system.
Unmanaged industrial Gigabit Ethernet switch for network networking and greater performance
The unmanaged Gigabit Ethernet switch provides networking for the various systems, including the controller, remote I/O islands and web panels. The switch provides the necessary performance for the high-speed data transmission required for real-time operations and process monitoring.
3. Operation and process optimisation
Android web panels for user-friendly operation and process optimisation
Several Android web panels are used to facilitate the operation of the system and save operators long walking distances. The web panels provide a user-friendly interface for monitoring and controlling the system, which improves efficiency and user-friendliness.
4. Safety management
Functional Safety modules for protection and monitoring
The safety modules monitor the function of the safety sensors and safety gates. They ensure the safe shutdown of connected contactors or drives in the event of safety events. The modules serve as power amplifiers for the safety components and ensure that safety requirements are met.
Architecture of the Project
Integration and communication
SAP® data processing: The Python container communicates with the ERP system to retrieve the required product data. This data is then passed on to the control unit.
Control and monitoring: The control logic in Codesys is executed on the AMAX controller, while Node-RED handles the visual programming and process monitoring.
Data flow and networking
Modbus TCP: Sensor and actuator data is transmitted from the remote I/O islands to the AMAX controller via Modbus TCP.
Ethernet switch: The unmanaged Gigabit Ethernet switch connects all network components and ensures fast and reliable data transmission.
Operation and Functional Safety
Web panels: The Android web panels allow operators to monitor and control the system, improving the efficiency of operations.
Safety modules: The safety modules ensure that all safety requirements are met and that the system is safely shut down in the event of a safety event.
Result
The system design offers a powerful, flexible, and secure solution for the automation of the carousel storage system, utilizing modern technologies to optimize operational processes.
By using Docker containers, the management of various software components is simplified, and system integration is optimized. Direct integration with the SAP system via Python reduces the need for additional hardware and interfaces. The combination of Node-RED, Python, and Codesys enables efficient and flexible control and monitoring of the system. The use of a Gigabit Ethernet switch ensures fast and reliable data transmission for real-time applications. The utilization of Android web panels improves user-friendliness and reduces the walking distances for operating personnel.
This comprehensive and modern automation solution increases efficiency, reduces manual effort, and improves accuracy in warehouse management.
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