Modernization and start-up of the automated high-bay warehouse system

Diplomsko delo podrobno opisuje proces posodobitve avtomatiziranega skladiščnega sistema. Gre za delno posodobitev, pri kateri obstoječ sistem nadgradimo z novimi krmilnimi napravami ter uporabniškima vmesnikoma. Namen diplomskega dela je prikaz lastnega prispevka k razvoju programske opreme in prilagoditvam po zagonu. V diplomskem delu je opisana teoretična podlaga, proces razvoja rešitve, testiranje in prilagajanje po zagonu in ponovni zagon skladiščnega sistema. Teoretično podlago pokrivajo priročniki, tehnični opisi proizvajalca opreme in strokovna literatura s področja avtomatizacije v okolju STEP7 (TIA Portal). Poleg tega so bili uporabljeni elektro načrti in navodila za uporabo vmesnikov. Posodobitev je predstavljena s poglavji o pripravi novega programskega okolja, odpravljanju napak, ki se pojavijo ob prenosu v novo okolje, ter razširitvi programske opreme za nova vmesnika. Uporaba teoretične podlage je privedla do nove rešitve, ki zajema vse funkcionalnosti starega sistema. Težišče dela je bil razvoj novih uporabniških vmesnikov. Nova uporabniška vmesnika nudita hitrejše rokovanje s sistemom, ker so zaslonski prikazi v novi rešitvi hitro dostopni ter jasni. Z manj prikazi dosežemo enako funkcionalnost, pri čemer uporabnik lažje in hitreje razloči funkcije, gumbe in prikaze. Proces razvoja rešitve je potekal najprej v simulacijskem okolju, potem na opremi in v skladišču ob zagonu. V vsaki fazi je nujno potrebno testiranje, ki pokaže napake in potrebe po prilagoditvah. Pred zagonom smo omejeni s povratnimi informacijami sistema, ki jih dobimo šele med zagonom. Ugotovljene potrebe po prilagoditvah so bile izvedene in v celoti preizkušene pri ponovnem zagonu sistema. V diplomski nalogi so izpostavljene pridobljene izkušnje, navedeni primeri rešitev programske kode in uporabniških vmesnikov za preizkušen končni produkt. Na koncu so zbrane ugotovitve in priporočila za posodabljanje avtomatiziranega skladiščnega sistema in vmesnikov.The thesis describes in detail the process of modernising an automated warehousing system. It represents a partial modernisation, where the existing system is upgraded with new control devices and user interfaces. The aim of the thesis is to demonstrate my own contribution to the software development and the adjustments after commissioning. The thesis describes the theoretical background, the process of developing the solution, the testing and adaptation after commissioning and the reboot of the warehousing system. The theoretical basis consists mainly of manuals and technical descriptions of the equipment manufacturer, literature in the field of automation in the STEP7 environment (TIA Portal). In addition, wiring diagrams and interface manuals were used. The update is presented with explanations on the development of the new software environment, the troubleshooting of errors occurring during the transfer to the new environment and the extension of the software for the new interfaces. The application of the theoretical background has led to a new solution that covers all the functionalities of the previous system. The focus of the work was on the development of new user interfaces. The new user interfaces offer a faster handling of the system because the screen displays in the new solution are quickly accessible and clear. With fewer displays, the same functionality is achieved, with the user being able to distinguish functions, buttons and displays more easily and quickly. The development process was carried out first in a simulation environment, then on the equipment in the warehouse at start-up. At each stage, testing is essential to show errors and the need for adjustments. Before commissioning, we are limited by the feedback we get from the system, which we only get during commissioning. The identified adjustment requirements have been implemented and fully tested in the system reboot. The thesis highlights the lessons learnt, gives examples of solutions to the software code and user interfaces for a good and reliable end-product. Finally, conclusions and recommendations for the modernisation of the automated warehouse system and interfaces are summarised