Emulation of a material delivery system

Emulation is the process of exactly imitating a real system. Recent advances in simulation technology make it possible to emulate real world control systems by using a system's control logic to interact with a simulation model. Routing logic, PLC or PC control software, sequencing algorithms, and more can be integrated, tested, and debugged within a simulation environment. Simulation models communicate with control software and provide animation and statistical-output for evaluating control logic and material handling systems. Traditionally, simulation models have been a good tool to test and refine system algorithms and control logic. However, once refined, the algorithms and logic must be re-implemented in the real system. One of the main benefits of emulation is that it eliminates the need to re-implement code. Because the actual control system is used to develop, test, and refine algorithms and logic, it exists as developed in the real system. This eliminates re-implementation errors and provides greater confidence in the emulation results. Emulation has been used for a Rapistan Systems project to test, debug, and optimize complex algorithms and control logic. Emulation of the complex pick and pack conveyor system is presented. The emulation approach and benefits that have been achieved are discussed.