Create and use mass flow conveyors

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In FlexSim, mass flow conveyors are a specialized type of conveyor

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used to simulate the continuous movement of bulk materials or products in a simulation model.

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Instead of simulating discrete units,

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this type of conveyor uses the density of products to calculate flow rates based on conveyor width and speed.

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You can use mass flow conveyors to create realistic and efficient simulations of continuous material handling processes,

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providing valuable insights for optimization, planning, and decision-making.

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Begin with FlexSim open to your model.

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In this example, a rectangular standard conveyor is shown to illustrate the differences between a standard and a mass flow conveyor.

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To add a mass flow conveyor, in the Library, click Mass Flow Conveyor, and then select Straight.

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Click in your model to anchor one end of the conveyor, and then click a second time to place it.

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Here, add four straight sections to the model in a rectangle to mirror the standard conveyor shown.

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Then, connect the ends of each straight section using Join Conveyor.

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Next, add a Source, and then connect it to the standard Conveyor.

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As the simulation is Run and stepped forward, notice that items flow onto the conveyor as discrete objects.

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Stop and Reset the simulation.

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Mass flow conveyors operate differently than the standard variety,

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allowing you to simulate the flow of high volumes of mass flow units using fluid logic.

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In the simulation, you will see discrete products on the mass flow conveyor, but this is purely for visualization.

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Rather than actual discrete units, this visualization represents the density of products.

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Select a mass flow conveyor, and then, in Properties, under Mass Flow Conveyor Behavior,

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set the Generative Rate to 50 units per second.

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Reset and Run the simulation to see the visualization of products on the conveyor.

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In this example, an error displays in the System Console to inform you that the mass flow conveyor has multiple inputs.

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While the Generative Rate is the intended single input, because this conveyor loops around,

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the conveyor adjacent to the selected conveyor is considered a second input.

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To fix this, window select the entire mass flow conveyor and press Delete, so that you can add a new one.

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In the Library, click Mass Flow Conveyor, select Straight, and then add the mass flow conveyor to the model.

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Add a Connection from the end of the conveyor, and then, from the Quick Library, add a Sink.

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Close the System Console.

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Select the new mass flow conveyor.

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In Properties, set the Generative Rate to 50.

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Reset and Run the simulation.

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You can see that the conveyor now automatically generates the flow items.

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Another way to generate the items on a mass flow conveyor is to use a Fixed Resource that produces flow items—

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—like a Source, Queue, or Processor—instead of Generative Rate.

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In the mass flow conveyor Properties, set the Generative Rate to 0.

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Add a Source to the model, and then, using an A Connection, connect it to the mass flow conveyor.

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Reset and Run the simulation,

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stepping it forward to see that the items generated by the Source are translated into mass flow items on the conveyor.

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Now, you can add mass flow conveyors to your 3D model to simulate continuous material handling processes.