Defining the Number of Mobile Robotic Systems Needed for Reconfiguration of Modular Manufacturing Systems via Simulation

Abstract

The European vision of the Factory of the Future is based on increasing competition and sustainability by transformation from cost orientation to high-adding value with technical and organisational innovations. One of the expected outcomes is an increase in modularisation, i.e., the reconfigurability of the technical system in manufacturing conditions. Modular manufacturing systems (MMS), will consist of modular platforms (MP) that are capable of rapid rebuilding, and reconfiguration performed by adding or removing a module by Mobile Robotic Systems (MRS). In the conditions of MMS, to make the most efficient use of reconfiguration MRS capacities, it is necessary to know the optimal ratio of these MRS to the number of modular platforms (MP) used in MMS, which does not exist today. This ratio will help industrial companies that are deploying MMS-based solutions to plan the number of MRSs needed to reconfigure deployed systems. As a method of determining this optimal ratio, an experimental approach via simulation was chosen, using data from custom MRS and MP prototypes with testing different layouts of modular platforms with the view of warehouse layout, manufacturing island, manufacturing island power supply, and MRS. Based on the results, it can be determined that the MP-MRS limit ratio is 2:1, where the further increase in MRS has only a minimal impact on the reconfiguration period. With the reduction of MP transferred to one MRS, there is a gradual decrease in the time required for reconfiguration. When the ratio of 1:1 is attained, the time required for reconfiguration lowers, but not as dramatically as in bigger ratios.