📐 TeraCalc3 Manual

TeraCalc3_Utility

Comprehensive Manual & Specification

Version 1.0.0 | Copyright: Logistics Technology Institute - Toshiyuki Teramoto

1. Overview

Program Name: TeraCalc3_UtilitySoft
Version: 1.0.0.0
Copyright: Logistics Technology Institute - Toshiyuki Teramoto
Expiration: 2026/12/31

TeraCalc3_Utility is a comprehensive logistics engineering software suite supporting various operational calculations. It integrates truck routing, container loading, pallet packing, and warehouse sizing algorithms into a unified package.

1.1 Key Characteristics

📊 Multi-function Integration

8 essential logistics calculation modules integrated into one platform.

🚛 Practical Engineering

Precise calculations based on actual vehicle and container dimensions.

📈 Visual Output

Graphical renderings of results to support intuitive understanding.

💾 Data Management

Save and load functions enabling iterative scenario testing.

1.2 Target Audience

  • DC and Warehouse Operations Managers
  • Transportation Planners
  • Process Improvement Engineers
  • Warehouse Layout Designers
  • Logistics Consultants

2. System Requirements

2.1 Operating Environment

Item Requirement
OS Windows 7 / 8 / 10 / 11
.NET Framework .NET Framework 4.5 or higher
RAM 4GB or more recommended
Disk Space 500MB free space
Display Resolution 1280×768 minimum

2.2 Required Third-Party Software

  • Microsoft Access Database Engine (For DB modules)
  • Microsoft Excel (For data export)
⚠ Note: The Tera計算Data folder must be placed at the root of drive A:, B:, C:, D:, E:, or F:.

3. Installation and Setup

3.1 Installation Steps

  1. Run the provided installer executable.
  2. Select the installation directory (default recommended).
  3. Follow the setup wizard to complete installation.
  4. Copy the Tera計算Data folder to a local root drive (A-F).

3.2 Initial Launch Setup

User Registration Process

  1. Upon first launch, a registration screen appears.
  2. Note the unique "Inquiry Number" displayed.
  3. Email this number to the copyright holder.
  4. Enter the returned "PIN Code" to activate.

Note: Registration is a one-time process.

3.3 Data Folder Structure

Folder / File Description
Tera計算Data\ Root master data folder
&├ SoftData\ Software configuration files
&├ PL積付計算\ Pallet loading simulation files
&├ フォーク積付通路計算\ Forklift aisle calculation files
&├ Tera計算.accdb Master Access Database
&└ SQL によるEIQ分析.accdb EIQ Analysis Database

4. Feature Catalog

TeraCalc3_Utility provides the following 8 primary modules.

4.1 Manual Calculation Methods

Overview

Educational module demonstrating baseline logistics mathematical formulas.

Features

  • Display of core logistics formulas.
  • Calculation examples.
  • Step-by-step logic breakdowns.

4.2 Inbound Space Sizing

Overview

Calculates required floor space for receiving areas.

Features

  • Volume-based footprint sizing.
  • Time-of-day arrival scheduling.
  • Temporary staging buffer calculation.

Inputs

  • Inbound case count
  • Case dimensions (L×W×H)
  • Operating hours
  • Space buffer ratio

4.3 Outbound Packing Volume

Overview

Calculates total shipped package dimensions and weights.

Features

  • Aggregation by package size.
  • Total cubic volume and weight.
  • Volume profiling by packaging type.

4.4 Outbound Space Sizing

Overview

Calculates required floor space for shipping operations.

Features

  • Volume-based footprint sizing.
  • Sorting area calculation by destination.
  • Picking zone footprint.
  • Shipping staging buffer calculation.

4.5 Truck Turning Radius & Trajectory

Overview

Calculates minimum turning radius and clearance aisles, rendering a visual trajectory map.

Features

  • Vehicle-specific turning trajectory.
  • Minimum turning radius calculation.
  • Required clearance (safety margin) calculation.
  • Trajectory graphic rendering and export.
  • Semi-trailer calculations.

Supported Vehicles

Category Vehicle Type
2-Ton Truck Standard cab/body, Wide cab/long body
4-Ton Truck Wide full cab, Standard full cab
Heavy Truck 16t (6x2), 15t (8x4), 11t dual front-axle
Container Chassis 20ft and 40ft container chassis

Input Parameters

  • Wheelbase
  • Front & rear overhang
  • Vehicle width
  • Minimum turning radius
  • Straight approach distance
  • Turn angle

4.6 Loose-Pick Container Routing

Overview

Calculates required tote/container counts for loose-piece shipping, applying EIQ optimization.

Features

  • Container volume sizing from raw shipment data.
  • Required count per container size.
  • Fill-rate optimization.
  • EIQ (Entry, Item, Quantity) profiling.
  • Aggregation by destination and date.
  • Pallet build calculation.

Supported Containers

Type Internal Dims (L×W×H) mm Volume (m³)
Oricon P-50B 530×366×336 0.0652
Oricon P-75B 654×434×336 0.0954

EIQ Module

  • E (Entry): Destination count ranking.
  • I (Item): SKU count ranking.
  • Q (Quantity): Volume aggregation.

4.7 Pallet Loading & Storage Sizing

Overview

Simulates optimal carton stacking patterns on pallets and calculates resulting storage scale.

Features

  • Algorithmic optimal load pattern generation.
  • Fill-rate efficiency scoring.
  • Required pallet count calculation.
  • Multi-tier stacking constraints.
  • Side-by-side pattern comparison.
  • Required storage rack tiers calculation.
  • Gross warehouse storage sizing.
  • Visual 2D top-down loading graphic.

Supported Pallets

Type Dimensions (L×W) mm
Standard T11 1100×1100
Standard T12 1200×1000
Custom User-defined

Heuristics

Generates multiple patterns and ranks them based on:

  • Average fill rate (surface area utilization).
  • Total pallet count (minimized).
  • Load stability (aspect ratio balance).

4.8 Forklift Aisle Width Calculation

Overview

Calculates required minimum aisle width for 90-degree right-angle stacking operations.

Features

  • Minimum aisle width per forklift type.
  • Calculations inclusive of pallet depth.
  • Configurable safety margin.
  • Right-angle turning trajectory math.
  • Visual dimensional drawing.

Supported Forklifts

Type Characteristics
Reach Truck Indoor use, tight turning radius.
Counterbalance (3-wheel) Balance of stability and maneuverability.
Catalog Spec Uses OEM catalog parameters.
Custom Input For specialized equipment.

Formula

Aisle Width = Forklift Total Length + Pallet Depth + Safety Margin

*Incorporates detailed trigonometric turn trajectory adjustments.

5. Usage Instructions

5.1 Basic Workflow

  1. Launch the application to open the main menu.
  2. Click the button corresponding to the desired module.
  3. Enter parameters in the specific module screen.
  4. Click "Calculate" or "Execute".
  5. Review the results.
  6. Export to Excel or save the profile if needed.

5.2 Example: Truck Trajectory

Steps

  1. Select "Truck Trajectory Calculation" from the menu.
  2. Select vehicle type (e.g., 2T Standard Cab).
  3. Input or adjust parameters:
    • Center coordinates (X,Y)
    • Wheelbase (mm)
    • Drawing scale
    • Straight approach length
  4. Click "Execute".
  5. View the rendered trajectory map.
  6. Review calculated minimum turning radius and clearance.

5.3 Example: Loose-Pick Container Sizing

Steps

  1. Select "Loose-Pick Container Calculation".
  2. Select target shipping date.
  3. Select container type.
  4. Set target fill rate (typically 60-80%).
  5. Click "Execute Container Sizing".
  6. Review results:
    • Volume by destination
    • Required container count
    • EIQ results
    • Required outbound pallets

5.4 Example: Pallet Loading Calculation

Steps

  1. Select "Pallet Loading & Storage Sizing".
  2. Load pallet master specs via Excel.
  3. Load carton dimension specs.
  4. Select target Pallet ID.
  5. Click "Execute Loading Calc".
  6. Review recommended patterns:
    • Fill rate per pattern
    • Required total pallets
    • 2D loading visual
  7. Sort results to find optimal pattern (by lowest PL count or highest fill rate).

5.5 Saving & Loading Data

Input data and results can be saved using the following methods:

  • Excel Export: Click "Excel Export" to save results as a spreadsheet.
  • Database: Certain modules automatically save to the Access DB.
  • Config Files: Previous session values are auto-loaded on next launch.

6. Technical Specifications

6.1 Development Environment

Item Detail
Language Visual Basic .NET
Framework .NET Framework 4.5+
IDE Visual Studio
Database Microsoft Access (ACCDB)
UI Framework Windows Forms

6.2 Libraries

  • System.Data.OleDb: Access connection provider.
  • ADODB: Legacy data access.
  • OfficeOpenXml (EPPlus): Excel spreadsheet generation.
  • Microsoft.Office.Interop.Excel: Native Excel interop.
  • Microsoft.Office.Interop.Access: Access application interop.

6.3 Application Files

File Name Description
Tera計算3_UtilitySoft.exe Main executable binary.
T3_UtilitySoft.vb Global module (variables, path checks).
T3_Uty0メニュー.vb Main Menu GUI.
T3_Uty1トラック軌跡計算.vb Truck Trajectory Module.
T3_Uty2バラ出荷コンテナ計算.vb Container Sizing Module.
T3_Uty3PL積付と保管規模.vb Pallet Loading Module.
T3_Uty4フォーク積付通路幅.vb Forklift Aisle Module.
T3_1_手計算方法.vb Manual Calc Display.
T3_2_入荷スペース.vb Inbound Space Module.
T3_3_梱包物量.vb Packing Volume Module.
T3_4_出荷スペース.vb Outbound Space Module.

6.4 Database Schema

Tera計算.accdb

Core Tables:

  • T000_出荷データ: Raw shipping history.
  • T230_日別集計: Daily aggregates.
  • トラック寸法マスタ: Rigid truck dimension master.
  • セミトレーラー寸法マスタ: Semi-trailer dimension master.

SQLによるEIQ分析.accdb

EIQ Engine Tables:

  • TF10_出荷コンテナ物量: Container shipping volume.
  • 集計テーブル: Internal temp aggregation tables.

6.5 Algorithm Logic Summaries

Truck Trajectory

Applies trigonometric functions to plot the coordinate path of the front/rear wheels and four vehicle corners during a turn.


Variables:
- Wheelbase
- Front/Rear Overhang
- Width
- Turn Angle
- Approach Distance

Steps:
1. Set start position
2. Calculate straight approach coordinates
3. Calculate turn arc coordinates (0.5 degree intervals)
4. Plot point array
5. Derive minimum turning radius
6. Calculate safety clearance envelope

Pallet Loading Optimization

Brute-force iteration across geometric orientations to find the highest-density stacking array.


Metrics:
1. Mean Fill Rate = (Total Box Area) / (Pallet Area) * 100
2. Pallet Count (minimize)
3. Load Stability

Method:
- Iterate through all valid longitudinal/latitudinal box alignments
- Calculate optimal fit per tier layer
- Rank top recommendations by fill rate and total pallet count

7. Troubleshooting

7.1 Launch Errors

❌ "Data Directory Does Not Exist"

Cause: The `Tera計算Data` folder is missing from the expected drive root.

Fix:

  • Ensure the folder is placed exactly at the root of A:, B:, C:, D:, E:, or F:.
  • Check for typos in the folder name (case sensitive).

❌ "Multiple Data Directories Exist"

Cause: The system detected `Tera計算Data` on more than one drive.

Fix:

  • Delete the duplicate folders. Keep only one instance on a single drive.

7.2 Database Errors

❌ Database Connection Failure

Cause: Missing Access drivers or corrupt .accdb file.

Fix:

  • Install Microsoft Access Database Engine 2016 Redistributable.
  • Ensure the database file is not corrupted.
  • Ensure the file is not set to Read-Only.

7.3 Excel Export Errors

❌ Excel Export Fails

Cause: Microsoft Excel missing or filesystem permission issues.

Fix:

  • Ensure a licensed version of Microsoft Excel is installed.
  • Verify write-permissions for the destination folder.
  • Check for sufficient free disk space.

7.4 Invalid Calculation Results

Audit Checklist

  • Verify unit inputs (mm vs cm vs m).
  • Check for numeric format errors (e.g., stray commas).
  • Ensure values are within realistic physical bounds.
  • Verify that Master Tables (truck dimensions) loaded properly.

7.5 Display Issues

UI Scaling Problems

  • Set monitor resolution to at least 1280×768.
  • Set Windows Display Scaling to exactly 100%.
  • Update graphics drivers.

7.6 Other Issues

Symptom Cause & Solution
Sluggish Performance - Expected during massive batch calculations.
- Close background apps to free RAM.
- Run "Compact & Repair" on the Access database.
Application Not Responding - Wait for background process to finish.
- Force-quit via Task Manager if totally hung, then restart.
- Verify data integrity in the database.
Cannot Print - Check printer driver installation.
- Ensure Default Printer is properly assigned.
- Export to Excel first, then print from Excel.

8. Appendix

8.1 Glossary

Term Definition
EIQ Analysis Order profile analysis based on Entry, Item, and Quantity dimensions.
Fill Rate Percentage of container/pallet volume effectively utilized by physical load.
Wheelbase Distance between front and rear axles.
Overhang Distance from axle to the outer bumper (Front/Rear).
Clearance Required safety margin between vehicle and static obstacles.
PL Pallet.
Reach Truck Stand-up forklift with extendable mast, designed for tight aisles.
Counterbalance Sit-down forklift utilizing rear counterweight.

8.2 Keyboard Shortcuts

Key Action
F1 Show Help
F5 Recalculate / Refresh
Ctrl + S Save Data
Ctrl + O Open File
Ctrl + P Print
Esc Close Dialog / Cancel

8.3 Revision History

Version Date Updates
1.0.0 2025 Initial Release

8.4 Support & Contact

Software Inquiries:

Copyright Holder: Logistics Technology Institute - Toshiyuki Teramoto

* Please provide your registered User Inquiry Number when contacting support.

8.5 License Information

End User License Agreement

  • This software is protected under copyright law.
  • Trial expiry: December 31, 2026.
  • Trial and Paid versions are subject to respective terms.
  • Unauthorized copying, distribution, or modification is prohibited.
  • The author assumes no liability for damages resulting from software use.

8.6 Reference Materials

  • Logistics Facility Design Standards (Japan Institute of Logistics Systems)
  • OEM Truck Dimension Catalogs
  • JIS Z 0602 Pallet Standards
  • Forklift Safety Guidelines (Industrial Safety and Health Regulations)