Virtual Plant Design: Automatic Sortation and Warehouse System for Distribution Intralogistics based on Petri-Net Method

Warehousing has a pivotal role in the distribution of goods across the supply chain. However, many manual processes still exist in intralogistics distribution, relying on employees to operate the system. This emphasizes the need for an automated intralogistics distribution system that incorporates automatic object sorter, which then feeds into palletizer followed by the use of cranes. The system utilizes a programmable logic controller (PLC) as a controller, with ladder diagrams as the programming language. The current approach to designing ladder diagrams lacks structure and can be challenging to solve problems efficiently. To address this, the petri net method is employed as a guide for programming, enabling the design of a more structured ladder diagram, and facilitating the characterization of discrete event simulation models. The ladder diagram’s results were recreated through simulation by employing a virtual plant implemented via Factory I/O, providing a close depiction of the logistics process within the manufacturing sector. The design result for intralogistics distribution in virtual plant involves the integration of 53 sensors and 68 actuators. The recorded time for distributing 25 palletized products to the warehouse averages at 17 minutes and 38 seconds.