Digital Twin Simulation Server for Dynamic Storage Capacity Adjustment
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Solution Overview
Problem
Current manufacturing logistics management systems lack efficient methods to optimize storage capacity and logistics efficiency in real-time, leading to suboptimal use of storage units and potential congestion or underutilization during manufacturing processes.
Innovation Solution
A simulation server based on digital twin technology that uses a database to store history and image data for virtual storage units, allowing for simulations to adjust the maximum storage capacity based on occupancy rates, and a management system that includes automated guided vehicles and sensors to monitor and control storage unit occupancy, ensuring optimal storage capacity utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If storage capacity is increased to prevent congestion, then logistics reliability is improved, but device complexity and space utilization worsen
Solution Approach 1:
The patent implements dynamic adjustment of storage capacity by adding or removing module image data based on simulated occupancy rates. The simulation server continuously monitors occupancy and automatically modifies the virtual storage unit configuration, transforming a static storage system into a dynamic one that adapts to changing logistics demands without manual intervention.
Solution Approach 2:
The patent creates a digital twin (virtual storage unit) that replicates the physical storage unit's characteristics and occupancy behavior. By simulating occupancy rates in the virtual environment and using these simulations to guide real storage capacity adjustments, the system avoids direct complex management of physical storage while maintaining reliability through the copied model.
2Productivity
If storage capacity is increased to ensure sufficient storage, then logistics efficiency is improved, but loss of space and resource utilization worsens
Solution Approach 1:
The patent implements a feedback loop where the simulation server continuously monitors occupancy rates of the virtual storage unit, compares them against threshold values, and automatically adjusts the number of module image data accordingly. This closed-loop feedback mechanism ensures storage capacity matches actual demand, preventing both congestion and underutilization.
Solution Approach 2:
The patent changes the parameter of storage capacity (number of module image data) based on simulated occupancy rate thresholds. When occupancy exceeds an upper threshold, modules are removed; when occupancy falls below a lower threshold, modules are added. This parameter adjustment optimizes space utilization while maintaining logistics efficiency.
3Device complexity
If manual adjustment of storage capacity is used, then device complexity is reduced, but loss of time and productivity worsen
Solution Approach 1:
The patent enables the storage management system to serve itself by automatically monitoring occupancy rates through the simulation server and adjusting storage capacity without human intervention. The system autonomously adds or removes module image data based on simulated conditions, eliminating the need for manual storage management while reducing adjustment time.
Solution Approach 2:
The patent performs preliminary simulation of occupancy rates before making actual storage capacity adjustments. By predicting future occupancy scenarios through digital twin simulation, the system proactively adjusts storage capacity in advance, preventing congestion before it occurs and avoiding reactive, time-consuming manual adjustments.
Data Source
AI summary
A simulation server includes: a database configured to store history data including an occupancy rate of an actual storage unit, wherein the database includes image data for a virtual storage unit corresponding to the actual storage unit to drive simulation using the digital twin; and a simulator apparatus configured to perform the simulation based on the history data and the image data, where the simulator apparatus is further configured to obtain a change amount of an occupancy rate of the virtual storage unit during the simulation, and change or maintain a maximum storage capacity of the virtual storage unit based on the change amount.