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EN
The article presents the results of the simulation studies concerning the impact of random production interruptions on the efficiency of multi-spindle machining centers. Four different machining center configuration models were developed using a dedicated class of stochastic Petri nets. In addition to the number of machine spindles, the number of simultaneously mounted parts, loading time of parts, their machining time, and reliability parameters regarding the frequency of machine interruptions caused by random factors were also taken into account as model parameters. A series of virtual tests was carried out for machining processes over a period of 1000 hours of operation. Analysis of the results confirmed the purpose of conducting simulation tests prior to making a decision regarding the purchase of a multispindle milling center. This work fills the existing research gap, as there are no examples in the technical literature of evaluating the effectiveness of multi-spindle machining centers.
EN
Quality profiling seeks to know the quality characteristics of products and processes to improve customer satisfaction and business competitiveness. It is required to develop new techniques and tools that upgrade and complement the traditional analysis of process variables. This article proposes a new methodology to model quality control of the process and product quality characteristics by applying optimization and simulation tools. The application in the production process of carbonated beverages allowed us to identify the most influential variables on the gas content and the degrees Brix of beverage.
EN
In order to fight climate change, the EU has set a goal of achieving net-zero greenhouse gas emissions by 2050. To achieve carbon neutrality, greenhouse emissions from human activities should be at least 85% lower than in 1990. The remaining 15% can be achieved through additional measures such as increasing carbon capture and storage (CCS) and reducing emissions. CCS will facilitate the decarbonization of heavy industry, contribute to the emergence of a clean hydrogen economy, and aid in achieving net-zero emissions. As an emerging technology in the Industry 4.0, Digital Twin (DT) is gaining attention due to the possibilities arising from its application, such as precise process optimization in the design phase, quality control, monitoring, decision-making, and through comprehensive modeling of the physical world as a group of connected digital models. The introduction of digital technologies into the CCS sector has the potential to revolutionize the way CO2 capture, transportation, and storage processes are carried out. This article aims to present the fundamental value of different modeling techniques, technologies enabling the creation of DT’s uncertainty quantification methods commonly used in Digital Twins, as well as the application of Digital Twin in CCS technology and the potential benefits it can bring, including increases efficiency and cost minimization. Additionally, the possibilities of using DS’s in improving process monitoring and forecasting were discussed which can contribute to better emission control and increases system effectiveness. Current research and projects utilizing this technology were also presented, including real-time modeling of fluid flow, CO2 transport network optimization, and storage process improvement.
PL
Celem artykułu jest porównanie wybranych narzędzi do modelowania i symulacji procesów biznesowych. Badanie porównawcze dotyczyło narzędzi Bizagi, Adonis, Bonita Studio i Visual Paradigm. Analiza ma na celu wskazanie najlepszego narzędziawedług określonych kryteriów. W artykule wyjaśniono pojęcia związane z procesami biznesowymi i przeanalizowano dotychczasową literaturę. Do analizy zostaną stworzone scenariusze badawcze zawierające kryteria oceny. Przeprowadzone badania wskazały, że najlepszym narzędziem spośród rozpatrywanych: Bizagi, Adonis, Bonita Studio, Visual Paradigm jest Bizagi
EN
The purpose of this article is to compare selected tools for modeling and simulating business processes. The comparative study concerned Bizagi, Adonis, Bonita Studio and Visual Paradigm tools. The analysis has the aim to identify the best tool according to the criteria.The article explains the concepts related to business processes and analyzes the existing literature. Research scenarios containing evaluation criteria will be created for the analysis. The conducted research indicated that the best tool among the considered: Bizagi, Adonis, Bonita Studio, Visual Paradigm is Bizagi.
EN
In the era of Industry 4.0, the digitization of production processes is one of the important elements contributing to the reduction of uncertainty related to the implementation of new production methods. The worldwide epidemic situation and its constraints have resulted in supply chain continuity problems. These problems make enterprises look for the possibility of producing products that they need at the moment and which they cannot obtain from the market. In special cases, this may also apply to spare parts necessary to maintain the continuity of production. The main reason for research on comparing production processes is meeting the challenges related to the pandemic situation and problems in maintaining timeliness, flexibility, and continuity of the supply chain. The first stage of the research was to visualize the course of the process and determine the lead times for both production methods. For further analysis, a digital process model was used to compare the hybrid and the classical method to check the viability of the interchangeability of methods for the production process of the flange part. The interchangeability of production methods was dictated by problems related to the supply of components for the execution of orders. The article simulates the model for unit and small-lot production in batches of 10 and 100 pieces, considering such aspects as: order completion time, energy consumption of the process, production costs, taking into account the classic and hybrid methods. The conducted research was aimed at determining the profitability of the production of flange-type products by means of classical processing and hybrid and checking the interchangeability of production methods in accordance with quality requirements as well as reducing uncertainty with the implementation of new production systems in changing market conditions. The simulations show that the use of hybrid production is recommended for unit production. In the case of small-lot production, already with 10 items, production in the traditional process is 21% cheaper, and for the production of 100 items, the cost of traditional production is reduced by 33% compared to hybrid production.
PL
Kwas azotowy(V) jest nieorganicznym związkiem chemicznym, który ze względu na silne właściwości utleniające wykorzystywany jest w wielu procesach przemysłu chemicznego, między innymi do wytwarzania paliwa rakietowego czy też rozdzielania mieszanin zawierających złoto i srebro. Kwas azotowy o niższym stężeniu (około 60 do 65 % mas. HNO3) zobojętnia się amoniakiem z wytworzeniem azotanu amonu, który ze względu na obecność dwóch form azotu (azotanowej i amonowej) stanowi podstawowy związek wchodzący w skład azotowych nawozów mineralnych. Znacząca większość HNO3 wytwarzanego w polskich zakładach chemicznych zużywana jest w procesie wytwarzania nawozów azotowych. W pracy przedstawiono wyniki symulacji komputerowej węzła absorpcji NOx w fazie ciekłej, stanowiącego jeden z ostatnich etapów syntezy kwasu azotowego(V) metodą Ostwalda. Określono także podstawowe parametry pracy pompy, wchodzącej w skład tej części instalacji.
EN
Nitric acid is an inorganic chemical compound, which due to its strong oxidizing properties is used as a substrate in many chemical industry processes, for example for rocket fuel synthesis or separation gold and silver containing mixtures. Nitric acid with lower concertation (about 60 to 65% by mass) is neutralized with ammonia to ammonium nitrate, which due to presence of two nitrogen forms (nitrate and ammonium) is a basic compound for nitrogen fertilizers. Most of HNO3 production in polish chemical companies is consumed as a substrate for nitrogen fertilizers production. This paper presented results of computer simulation for NOx absorption process in liquid phase, which is one of the last step in the HNO3 synthesis by Ostwald method. The basic work parameters of pump for this part of installation were also calculated.
PL
W artykule przedstawiono próbę oceny właściwości mechanicznych próbek z wysokowytrzymałych stopów aluminium AlZnMgCu odlewanych do form gipsowych. Pierwszy etap realizacji prac obejmował wykorzystanie symulacji komputerowej w celu wybrania optymalnej konstrukcji złożenia próbek. W tym celu wykorzystano oprogramowanie do modelowania CA D – SolidWorks (opracowanie geometrii złożenia) oraz środowisko do symulacji procesu odlewania oraz krzepnięcia – Flow3D. Wyniki zostały przedstawione w postaci wizualizacji wypełniania wnęki formy oraz krzepnięcia odlewów. W celu weryfikacji właściwości wytrzymałościowych stopu wykonane zostały odlewy próbek wytrzymałościowych. Procedura wykonywania odlewów była powtarzana dla form gipsowych, które po wypaleniu były schłodzone do różnych temperatur przed ich zalewaniem.
EN
The paper presents an attempt to assess the mechanical properties of high-strength AlZnMgCu aluminium alloy samples cast in gypsum moulds. The first stage of the study involved the use of computer simulations to select the optimum sample assembly structure. To this end, the SolidWorks CA D software (assembly geometry design) and Flow3D casting and solidification simulation environment were used. The results are presented as mould cavity filling and cast solidification visualisations. To verify the strength properties of the alloy, strength test samples were prepared. The cast production procedure was repeated for gypsum moulds, which were cooled down to different temperatures after their firing and before filling.
EN
This article covers the use of supplementary firing in a gas-combined cycle power plant when high flexibility is required depending on the penetration of variable renewable energies and under different gas turbine loads. Process models were simulated under different operating conditions with the software EBSILON® Professional. Five main conditions were studied for the designed combined cycle: gas turbine part-load without supplementary firing, gas turbine full load with supplementary firing, the use of supplementary firing to overcome the effect of changing ambient conditions, part-load gas turbine performance with supplementary firing technology and the use of supplementary firing in case of gas turbine shutdown.
EN
Because of the low quality, middlings from the coal preparation often remain unused and are stored on the industrial site or simply landfilled. The authors offer a possible solution to this problem; its main idea is to upgrade the flowsheet of the coal processing plant by recycling the by-product that will turn it into valuable concentrate. Such approach would increase the efficiency of processing, allow comprehensive utilization of mineral raw materials, reduce the loss of combustible matter from coal with rejects, and would result in higher revenue from the sales of high-quality coal concentrate. This article represents outcomes of the studies of coarse coal middlings as potential raw material for producing sellable concentrate. The middlings are obtained from a coal preparation plant located in Kuznetsk coal basin, Russia. Samples have been crushed down to a size of 13 mm, and then a float-sink analysis has been completed from which the liberation degree is calculated. Performance of gravity separation and flotation of slimes has been evaluated with a laboratory scale equipment. It is shown that middlings of the coking coal have high potential to yield a high-quality concentrate. Forecasted mass balance of the proposed flowsheet for the middlings reprocessing shows that 50 to 80% of total middlings production might be transformed into low-ash coal concentrate.
PL
Ze względu na niską jakość, półprodukty z wzbogacania węgla często pozostają niewykorzystane i są przechowywane na terenach przemysłowym lub po prostu składowane na składowisku. Autorzy proponują rozwiązanie problemu wykorzystania przerostów; główną ideą jest modernizacja schematu technologicznego zakładu przeróbki węgla poprzez wzbogacanie produktu pośredniego, który pozwoli uzyskać koncentrat handlowy. Takie podejście zwiększy wydajność przeróbki, pozwala na kompleksowe wykorzystanie surowców mineralnych, ograniczają straty substancji palnej z węgla i będą generować wyższe przychody ze sprzedaży wysokiej jakości koncentratu węgla. W artykule przedstawiono wyniki badań półproduktów z wzbogacania węgla kamiennego jako potencjalnego surowca do produkcji koncentratu handlowego. Zakład wzbogacania jest zlokalizowany w Zagłębiu Kuźnieckim w Rosji. Próbki zostały rozdrobnione do wielkości 13 mm, a następnie przeprowadzono analizę densymetryczną i poddano separacji grawitacyjnej i flotacji w warunkach laboratoryjnych. Wykazano, że półprodukty z przeróbki węgla koksowego mają duży potencjał do uzyskania wysokiej jakości koncentratu. Prognozowany bilans masowy proponowanego schematu dla wtórnego wzbogacania półproduktów pokazuje, że 50 do 80% całkowitej ilości półproduktów można wzbogacić w celu uzyskania koncentratu węgla o niskiej zawartości popiołu.
EN
In this paper we focus on the implementation of a process flow of SB-MOSFETs into the process simulator of the Synopsys TCAD Sentaurus tool-chain. An improved structure containing topography is briefly discussed and further device simulations are applied with the latest physical models available. Key parameters are discussed and finally the results are compared with fabricated SB-MOSFETs in terms of accuracy and capability of process simulations.
EN
Screw presses are energy-restricted forming machines that use rotational energy stored in a flywheel for forming, which is converted into a linear movement by a threaded screw. Screw presses are widely used for forging steel, aluminum and brass. In a direct-driven electrical screw press, a reversible electric motor is mounted directly on the screw and on the press frame above the flywheel. With directly driven screw presses, the blow energy can be exactly dosed from one blow to the next. However, so far no prior work is known which uses the blow energy as a control input in a targeted manner to influence the properties of the forging. The purpose of the present work is to lay the foundations for property control through blow energy dosing during forging on screw presses. Process control becomes increasingly interesting due to ever increasing customer demands and needs for resource-efficient production. A major challenge is the variation of process parameters, e.g. temperature variations in the furnace, during transport or due to inherent uncertainty in the heat transfer to the dies and the environment. If the process conditions are changing the deviations from the planned process trajectory may lead to an insufficient die filling or undesired final properties. Forged parts require high precision considering the part geometry and material properties. During forming two mechanisms in terms of forming temperature take place: heat conduction due to contact with tools and heat dissipation due to plastic deformation. The heat transfer acts as disturbance, the impact energy can be used as control input. In this work, investigations into process control by impact energy dosing are put forward using FE (finite element) simulations.
EN
The paper addresses the issues of quantification and understanding of Solid Oxide Fuel Cells (SOFC) based on numerical modelling carried out under four European, EU, research projects from the 7FP within the Fuel Cell and Hydrogen Joint Undertaking, FCH JU, activities. It is a short review of the main projects’ achievements. The goal was to develop numerical analyses at a single cell and stack level. This information was integrated into a system model that was capable of predicting fuel cell phenomena and their effect on the system behaviour. Numerical results were analysed and favourably compared to experimental results obtained from the project partners. At the single SOFC level, a static model of the SOFC cell was developed to calculate output voltage and current density as functions of fuel utilisation, operational pressure and temperature. At the stack level, by improving fuel cell configuration inside the stack and optimising the operation conditions, thermal stresses were decreased and the lifetime of fuel cell systems increased. At the system level, different layouts have been evaluated at the steady-state and by dynamic simulations. Results showed that increasing the operation temperature and pressure improves the overall performance, while changes of the inlet gas compositions improve fuel cell performance.
13
Content available remote Combined heat and power plant on offshore oil and gas installations
EN
Implementation of energy efficient technologies is an issue of growing importance for the offshore oil and gas industry. Rising awareness of increasing levels of CO2in the atmosphere is a major driver in this move, with a main aim being to reduce the amount of released CO2 per unit of oil or natural gas produced. Subsequently, the addition of steam bottoming cycles to exploit exhaust heat from gas turbines offshore has become an attractive alternative. This paper will investigate two different combined cycle configurations, namely the extraction steam turbine- and the backpressure steam turbine-cycle. Both cycles were modelled using the process simulation software Ebsilon Professional with a single GE LM2500+G4 gas turbine as a topping cycle, and a once-through heat recovery steam generator to exploit GT exhaust heat. At design, the steam turbines produced 8.2 MW and 6.0 MW respectively, achieving net thermal efficiency of 45.5%/42.1%. This was a 12.3 pp/8.9 pp increase compared to the simple cycle GE LM2500+G4 configuration. The findings suggest that a backpressure steam turbine could be an attractive option for oil producing facilities with high demand for process heat, while an extraction steam turbine configuration is more suited to gas producing facilities with lower heat requirements and a higher demand for power and flexibility. Additionally, both cycles displayed a substantial reduction in emitted CO2 per MWh produced, with reductions 26% and 21% compared to the simple cycle configuration achieved for the extraction and backpressure cycle respectively.
14
Content available Coal Preparation from Geometallurgical Perspective
EN
Geometallurgy as a link connecting geological features of deposit with metallurgical performance of a concentrator have found broad utilization in metals mining as well as for industrial minerals and black sands mining. However, coal industry yet stays uncovered by successful applications of geometallurgical approach due to certain specifics of a commodity. Production of coal preparation plant in terms of quality and quantity can be forecasted knowing behavior of coal bearing particles in process that is controlled by petrological and mineralogical properties. Application of process mineralogical tools together with comprehensive metallurgical testwork helps to acquire essential information for a simulation of coal preparation operations. Being combined with geological, geochemical and geotechnical data available for a deposit, outcome of process simulation will form holistic geometallurgical model. Once implemented, such models will become a powerful instrument for efficient utilization of resources and proper risk management, e.g. adaptation of the process to variations in run-of-mine coal quality, “what-if” analysis of alternative production strategies, forecasting of financial results, assessment of environmental impact.
PL
Geometalurgia jest to ogniwo łączące cechy geologiczne złoża z wydajnością zakładów metalurgicznych, geometalurgia znalazła zastosowanie w górnictwie metali i innych surowców. Najważniejsze zastosowanie geometalurgia znalazła w przemyśle węglowym. Geometalurgia pozwala przewidzieć wielkość i jakośc produkcji zakładu wzbogacania węgla wynikające z właściwości petrologicznych i mineralogicznych minerałów w złożu. Zastosowanie narzędzi geometalurgicznych do analizy danych pomaga uzyskać kluczowe informacje dla symulacji procesów wzbogacania węgla. Połączenie danych geologicznych, geochemicznych i geotechnicznych umożliwiają przeprowadzenie symulacji procesu wzbogacania na bazie opracowanych modeli. Po wdrożeniu modele staną się instrumentem efektywnego wykorzystania zasobów i właściwego zarządzania ryzykiem, dostosowanie procesu do zmian jakości węgla w trakcie eksploatacji, analiza alternatywnych strategii produkcyjnych, prognozowanie wyników finansowych, ocena oddziaływania na środowisko.
EN
By integrating sensors and actuators, intelligent machine tool components can be realized, which allow the monitoring of machining processes and machine tool states and an active influencing of process conditions. In the design and layout of these intelligent machine tool components, their mechanical structure and the functional performance of the sensor and actuator sub-systems have to be optimized. As an example, a sensor and actuator integrated fixture system for clamping large but sensitive aerospace structural parts is presented here. In order to investigate the major influences of design approaches on the behaviour of the workpiece and fixture, especially with respect to vibrations and process stability during milling, multiple test rigs and prototypes for basic analyses and machining tests were developed and realized. Experimental and Finite Element Analysis (FEA) results are presented and discussed. Process simulations were conducted taking the dynamic behaviour of the clamped workpiece at different processing steps into account. This simulation can be used for predicting the limits of the process stability. An approach of sensor and actuator integration is described and test results are shown. The paper introduces a principle design and layout methodology for similar intelligent machine tool components.
EN
The paper presents a new approach to monitoring changes of characteristic parameters of gravitational solids flow. Electrical Capacitance Tomography (ECT) is applied for non-invasive process monitoring. Artificial Neural Networks (ANN) are used to estimate important flow parameters knowing the measured capacitances. The proposed approach solves the ECT inverse problem in a direct manner and provides a rapid parameterization of the funnel flow. The simulation of the silo discharging process is performed relying on real flow behaviour obtained from the authors’ previous work. The simulated data are used to new approach testing and verification. The obtained results proved that proposed ANN-based method will allow for on-line gravitational solids flow monitoring.
PL
W artykule opisano nowe podejście do monitorowania zmian charakterystycznych parametrów przepływu grawitacyjnego. Do nieinwazyjnego monitorowania procesu stosowana jest Elektryczna Tomografia Pojemnościowa (ECT). Sztuczne Sieci Neuronowe wykorzystywane są do estymacji ważnych parametrów przepływu na podstawie mierzonych pojemności. Zaproponowane podejście pozwala na rozwiązanie problemu odwrotnego w ECT w sposób bezpośredni i umożliwia natychmiastową parametryzację przepływu kominowego. Symulacja procesu rozładowania silosu została wykonana na podstawie wyników wcześniejszych badań eksperymentalnych przeprowadzonych na rzeczywistym obiekcie. Dane symulacyjne wykorzystano do testowania i weryfikacji nowego podejścia. Uzyskane wyniki wykazały, iż zaproponowana metoda wykorzystująca Sztuczne Sieci Neuronowe pozwoli na monitorowanie on-line parametrów przepływu grawitacyjnego.
EN
US A356 and US 413 cast aluminium alloys shrinkage characteristic have been discussed in the present study. Specific volume reduction leads to shrinkage in castings and it can be envisaged as a casting defect. Finite difference based casting process simulation software has been used to study the shrinkage characteristic and it is quantified using mathematical formulae. The three dimensional model of the shrinkage defect has been constructed using CAD application software. Shrinkage characteristic has also been quantified through experimental validation studies and compared well with casting process simulation. Shrinkage characteristic study and control is essential for producing defect free castings. Influence of casting shape on the shrinkage characteristic has been studied in this paper.
18
Content available Application for simulating gyro-compass behavior
EN
Resolution of International Maritime Organization (IMO Res. A.424 (XI)), International Convention for the Safety of Life at Sea (SOLAS V/19.2.5) and consequently ‘Provisions Survey of Ships Marine’, part V, contained in the Polish Register of Shipping impose an obligation to fit ships with gyro-compass as one of the most complex marine equipment has found in the curricula of seafarers at the operational level (IMO Model Course 7.03). Curriculum involves the use real navigation devices. In addition, the adaptation of teaching facilities to meet the needs of the training process often requires the development of educa-tional aids in the form of simulators and applications that represent the construction and operation of navigation devices. The article presents possibilities of the application — gyro-compass simulator developed for the requirements of the Institute of Navigation and Maritime Hydrography PNA. Among others, the program is used to simulate the conditions in which you can expect the occurrence of different types of gyro-compass deviation. Designed software is expected to improve the educational process, to help the students assimilate the content of the curriculum in the field of classic gyro-compasses and familiarize trainees with static and dynamic errors occurring with the change of operating conditions.
PL
Obowiązek wyposażenia jednostek pływających w urządzenia żyrokompasowe reguluje rezolucja Międzynarodowej Organizacji Morskiej (IMO Res. A.424 (XI), międzynarodowa konwencja o bezpieczeństwie życia na morzu (SOLAS V/19.2.5) i w konsekwencji zawarte w Polskim Rejestrze Statków „Przepisy nadzoru konwencyjnego statków mor-skich”, cz. V. Tematyka dotycząca kompasów żyroskopowych jako jednych z najbardziej złożonych urządzeń okrętowych znalazła miejsce w programach nauczania kadr morskich na poziomie operacyjnym (IMO Model Course 7.03). Program szkolenia przewiduje wykorzystanie faktycznych urządzeń nawigacyjnych. Dodatkowo dostosowanie bazy dydaktycznej do potrzeb procesu szkolenia często wymaga opracowania pomocy naukowych w postaci symulatorów i programów przedstawiających budowę i zasadę działania urządzeń nawigacyjnych. Artykuł prezentuje możliwości aplikacji symulującej kompas żyroskopowy, opracowanej na potrzeby Instytutu Nawigacji i Hydrografii Morskiej AMW. Program służy między innymi do symulowania warunków, w jakich można spodziewać się występowania różnych typów dewiacji żyrokompasowych. Zaprojektowane oprogramowanie ma uskutecznić proces dydaktyczny, pomóc słuchaczom przyswoić treści programowe z zakresu klasycznych kompasów żyroskopowych oraz zapoznać szkolonych z błędami statycznymi i dynamicznymi pojawiającymi się wraz ze zmianą warunków pracy urządzenia.
EN
A proper selection of steam reforming catalyst geometry has a direct effect on the efficiency and economy of hydrogen production from natural gas and is a very important technological and engineering issue in terms of process optimisation. This paper determines the influence of widely used seven-hole grain diameter (ranging from 11 to 21 mm), h/d (height/diameter) ratio of catalyst grain and Sh/St (hole surface/total cylinder surface in cross-section) ratio (ranging from 0.13 to 0.37) on the gas load of catalyst bed, gas flow resistance, maximum wall temperature and the risk of catalyst coking. Calculations were based on the one-dimensional pseudo-homogeneous model of a steam reforming tubular reactor, with catalyst parameters derived from our investigations. The process analysis shows that it is advantageous, along the whole reformer tube length, to apply catalyst forms of h/d = 1 ratio, relatively large dimensions, possibly high bed porosity and Sh/St ≈ 0.30-0.37 ratio. It enables a considerable process intensification and the processing of more natural gas at the same flow resistance, despite lower bed activity, without catalyst coking risk. Alternatively, plant pressure drop can be reduced maintaining the same gas load, which translates directly into diminishing the operating costs as a result of lowering power consumption for gas compression.
PL
Artykuł dotyczy nowoczesnego programu służącemu do symulacji FlexSim Simulation Software. W artykule znajduje się opis, czym jest symulacja i jak wpływa na rozwój. Przedstawiono również opis programu FlexSim, jakie posiada on zalety oraz wady. W artykule znajdują się zrzuty ekranowe, wraz z opisem, wykonanej przez autorów przykładowej symulacji w opisywanym programie.
EN
This article is about modern program to simulation FlexSim Simulation Software. In the article is a description what is the simulation and how help in development. It also presents a description of the FlexSim program and his advantages and disadvantages. In the article are screenshots with description, made example simulation in describe program by the authors.
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