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Modelling and Performance Analysis of a Robotic Assembly System for Large Scale Plate Mounting

Manteus, Paul LU and Trane Lindberg, Niclas LU (2026) MIOM05 20261
Department of Industrial and Mechanical Sciences
Production Management
Abstract
As industrial sectors and digital infrastructure expand, the global demand for high-volume, reliable manufacturing of thermal management solutions like heat exchangers continues to accelerate. This thesis investigates the design and optimization of an automated robotic assembly cell for heat exchanger production at Alfa Laval using Discrete Event Simulation (DES). The primary objective was to define the optimal configurations and operational strategies for a new vertical Automated Storage Elevator system.

Through quantitative evaluation of physical parameters, the simulation results demonstrate that a twin-elevator architecture paired with eight storage compartments strikes the optimal operational balance. The parallel twin-elevator... (More)
As industrial sectors and digital infrastructure expand, the global demand for high-volume, reliable manufacturing of thermal management solutions like heat exchangers continues to accelerate. This thesis investigates the design and optimization of an automated robotic assembly cell for heat exchanger production at Alfa Laval using Discrete Event Simulation (DES). The primary objective was to define the optimal configurations and operational strategies for a new vertical Automated Storage Elevator system.

Through quantitative evaluation of physical parameters, the simulation results demonstrate that a twin-elevator architecture paired with eight storage compartments strikes the optimal operational balance. The parallel twin-elevator design maximizes system efficiency by completely masking upstream pallet transport times, thereby protecting the primary system constraint: the Plate Hanging Robot (PHR). Sensitivity and reliability stress-testing revealed high project viability and resilience. Even when mechanical faults drop the effective utilization of the PHR, the automated cell successfully matches or exceeds the throughput of the legacy manual assembly line. Finally, while the 8-compartment architecture maximizes operational autonomy and throughput, it introduces higher capital expenditure. Therefore, future work must incorporate a comprehensive financial cost-benefit analysis to determine the final setup. (Less)
Popular Abstract
Heat exchangers are one of the quiet workhorses of this modern technological world, transferring excess heat to keep everything from global food production and maritime transport to massive digital data centers running safely without overheating. As our reliance on digital services and industrial manufacturing grows, the demand for these vital machines is skyrocketing. To keep up, factories must transition from traditional, manual assembly lines to fast, reliable robotic systems.

This project utilized advanced computer simulations to design and test a brand-new, fully automated robotic manufacturing cell for Alfa Laval. The core of the new system is a vertical storage tower that feeds parts to assembly robots via automated elevators.... (More)
Heat exchangers are one of the quiet workhorses of this modern technological world, transferring excess heat to keep everything from global food production and maritime transport to massive digital data centers running safely without overheating. As our reliance on digital services and industrial manufacturing grows, the demand for these vital machines is skyrocketing. To keep up, factories must transition from traditional, manual assembly lines to fast, reliable robotic systems.

This project utilized advanced computer simulations to design and test a brand-new, fully automated robotic manufacturing cell for Alfa Laval. The core of the new system is a vertical storage tower that feeds parts to assembly robots via automated elevators. The big challenge was finding the perfect balance: how many storage shelves and elevators do we actually need to maximize production without driving equipment costs through the roof?

The digital experiments revealed a clear winner. A parallel system utilizing two elevators and eight storage shelves struck the ultimate sweet spot. This design allows twin elevators work in tandem, they completely hide transport delays, keeping the main assembly robot continuously fed with parts. The simulation showed that this automated system has the potential to be very resilient. Even if mechanical breakdowns slow the main robot down to less than half its maximum capability, the automated cell still easily matches the output of the current human assembly line. While adding a second elevator requires a higher upfront cost, it gives the factory a major boost in independence, letting operators step away for long, predictable blocks of time while the machines handle the heavy lifting. (Less)
Please use this url to cite or link to this publication:
author
Manteus, Paul LU and Trane Lindberg, Niclas LU
supervisor
organization
alternative title
How Robots Are Revolutionizing Heat Exchanger Assembly at Alfa Laval
course
MIOM05 20261
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Discrete Event Simulation (DES) Production Automation Production Logistics Sensitivity and Reliability Testing Bottleneck Analysis
other publication id
26/5338
language
English
id
9228920
date added to LUP
2026-06-03 17:17:52
date last changed
2026-06-03 17:17:52
@misc{9228920,
  abstract     = {{As industrial sectors and digital infrastructure expand, the global demand for high-volume, reliable manufacturing of thermal management solutions like heat exchangers continues to accelerate. This thesis investigates the design and optimization of an automated robotic assembly cell for heat exchanger production at Alfa Laval using Discrete Event Simulation (DES). The primary objective was to define the optimal configurations and operational strategies for a new vertical Automated Storage Elevator system.

Through quantitative evaluation of physical parameters, the simulation results demonstrate that a twin-elevator architecture paired with eight storage compartments strikes the optimal operational balance. The parallel twin-elevator design maximizes system efficiency by completely masking upstream pallet transport times, thereby protecting the primary system constraint: the Plate Hanging Robot (PHR). Sensitivity and reliability stress-testing revealed high project viability and resilience. Even when mechanical faults drop the effective utilization of the PHR, the automated cell successfully matches or exceeds the throughput of the legacy manual assembly line. Finally, while the 8-compartment architecture maximizes operational autonomy and throughput, it introduces higher capital expenditure. Therefore, future work must incorporate a comprehensive financial cost-benefit analysis to determine the final setup.}},
  author       = {{Manteus, Paul and Trane Lindberg, Niclas}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Modelling and Performance Analysis of a Robotic Assembly System for Large Scale Plate Mounting}},
  year         = {{2026}},
}