An approach to task coordination for hyperflexible robotic workcells

2014 - 2015The manufacturing industry is very diverse and covers a wide range of specific processes ranging from extracting minerals to assembly of very complex products such as planes or computers, with all intermediate processing steps in a long chain of industrial suppliers and customers. It is well know that the introduction of robots in manufacturing industries has many advantages. Basically, in relation to human labor, robots work to a constant level of quality. For example, waste, scrap and rework are minimized. Furthermore they can work in areas that are hazardous or unpleasant to humans. Robots are advantageous where strength is required, and in many applications they are also faster than humans. Also, in relation to special-purpose dedicated equipment, robots are more easily reprogrammed to cope with new products or changes in the design of existing ones. In the last 30-40 years, large enterprises in high-volume markets have managed to remain competitive and maintain qualified jobs by increasing their productivity with the incremental adoption and use of advanced ICT and robotics technologies. In the 70s, robots have been introduced for the automation of a wide spectrum of tasks such as: assembly of cars, white goods, electronic devices, machining of metal and plastic parts, and handling of workpieces and objects of all kinds. Robotics has thus soon become a synonym for competitive manufacturing and a key contributing technology for strengthening the economic base of Europe . So far, the automotive and electronics industries and their supply chains are the main users of robot systems and are accounting for more than 60% of the total annual robot sales. Robotic technologies have thus mainly been driven by the needs of these high-volume market industries. The degree of automation in the automotive industries is expected to increase in the future as robots will push the limits towards flexibility regarding faster change-over-times of different product types (through rapid programming generation schemes), capabilities to deal with tolerances (through an extensive use of sensors) and costs (by reducing customized work-cell installations and reuse of manufacturing equipment). There are numerous new fields of applications in which robot technology is not widespread today due to its lack of flexibility and high costs involved when dealing with varying lot sizes and variable product geometries. In such cases, hyper-flexible robotic work cells can help in providing flexibility to the system and making it adaptable to the different dynamic production requirements. Hyper-flexible robotic work cells, in fact, can be composed of sets of industrial robotic manipulators that cooperate to achieve the production step that characterize the work cell; they can be programmed and re-programmed to achieve a wide class of operations and they may result versatile to perform different kind of tasks Related key technology challenges for pursuing successful long-term industrial robot automation are introduced at three levels: basic technologies, robot components and systems integration. On a systems integration level, the main challenges lie in the development of methods and tools for instructing and synchronising the operation of a group of cooperative robots at the shop-floor. Furthermore, the development of the concept of hyper flexible manufacturing systems implies soon the availability of: consistent middleware for automation modules to seamlessly connect robots, peripheral devices and industrial IT systems without reprogramming everything (”plug-and-play”) . In this thesis both innovative and traditional industrial robot applications will be analyzed from the point of view of task coordination. In the modeling environment, contribution of this dissertation consists in presenting a new methodology to obtain a model oriented to the control the sequencing of the activities of a robotic hyperflexible cell. First a formal model using the Colored Modified Hybrid Petri Nets (CMHPN) is presented. An algorithm is provided to obtain an automatic synthesis of the CMHPN of a robotic cell with detail attention to aircraft industry. It is important to notice that the CMHPN is used to model the cell behaviour at a high level of abstraction. It models the activities of each cell component and its coordination by a supervisory system. As more, an object oriented approach and supervisory control are proposed to implement industrial automation control systems (based on Programmable Logic Controllers) to meet the new challenges of this field capability to implement applications involving widely distributed devices and high reuse of software components. Hence a method is proposed to implement both controllers and supervisors designed by Petri Nets on Programmable Logic Controllers (PLCs) using Object Oriented Programming (OOP). Finally preliminary results about a novel cyber-physical approach to the design of automated warehouse systems is presented. [edited by author]XIV n.s

Foundations of Multi-Paradigm Modelling for Cyber-Physical Systems

This open access book coherently gathers well-founded information on the fundamentals of and formalisms for modelling cyber-physical systems (CPS). Highlighting the cross-disciplinary nature of CPS modelling, it also serves as a bridge for anyone entering CPS from related areas of computer science or engineering. Truly complex, engineered systems—known as cyber-physical systems—that integrate physical, software, and network aspects are now on the rise. However, there is no unifying theory nor systematic design methods, techniques or tools for these systems. Individual (mechanical, electrical, network or software) engineering disciplines only offer partial solutions. A technique known as Multi-Paradigm Modelling has recently emerged suggesting to model every part and aspect of a system explicitly, at the most appropriate level(s) of abstraction, using the most appropriate modelling formalism(s), and then weaving the results together to form a representation of the system. If properly applied, it enables, among other global aspects, performance analysis, exhaustive simulation, and verification. This book is the first systematic attempt to bring together these formalisms for anyone starting in the field of CPS who seeks solid modelling foundations and a comprehensive introduction to the distinct existing techniques that are multi-paradigmatic. Though chiefly intended for master and post-graduate level students in computer science and engineering, it can also be used as a reference text for practitioners

Study applying simulation to improve a real production process in the context of Industry 4.0

During the thesis development, simulation theories and techniques will be applied to a part of the production process of an Italian manufacturing company. A simulation model of the steaming and washing phases will be developed to outline the automated and manual procedures that are performed in the AS-IS state. Several what-if scenarios will be then envisioned and simulated to analyze how the production activities could be re-engineered in the light of the new technological advancements, such as the introduction of full traceability

Industrial Applications: New Solutions for the New Era

This book reprints articles from the Special Issue "Industrial Applications: New Solutions for the New Age" published online in the open-access journal Machines (ISSN 2075-1702). This book consists of twelve published articles. This special edition belongs to the "Mechatronic and Intelligent Machines" section

Search-based system architecture development using a holistic modeling approach

This dissertation presents an innovative approach to system architecting where search algorithms are used to explore design trade space for good architecture alternatives. Such an approach is achieved by integrating certain model construction, alternative generation, simulation, and assessment processes into a coherent and automated framework. This framework is facilitated by a holistic modeling approach that combines the capabilities of Object Process Methodology (OPM), Colored Petri Net (CPN), and feature model. The resultant holistic model can not only capture the structural, behavioral, and dynamic aspects of a system, allowing simulation and strong analysis methods to be applied, it can also specify the architectural design space. Both object-oriented analysis and design (OOA/D) and domain engineering were exploited to capture design variables and their domains and define architecture generation operations. A fully realized framework (with genetic algorithms as the search algorithm) was developed. Both the proposed framework and its suggested implementation, including the proposed holistic modeling approach and architecture alternative generation operations, are generic. They are targeted at systems that can be specified using object-oriented or process-oriented paradigm. The broad applicability of the proposed approach is demonstrated on two examples. One is the configuration of reconfigurable manufacturing systems (RMSs) under multi-objective optimization and the other is the architecture design of a manned lunar landing system for the Apollo program. The test results show that the proposed approach can cover a huge number of architecture alternatives and support the assessment of several performance measures. A set of quality results was obtained after running the optimization algorithm following the proposed framework --Abstract, page iii

Simulation Modelling Practice and Theory

The influx of data in the world today needs analysis that no one method can handle. Some reports estimated the influx of data would reach 163 zitabytes by 2025, hence the need for simulation and modeling theory and practice. Simulation and modeling tools and techniques are most important in this day and age. While simulation carries the needed work, tools for visualizing the results help in the decision-making process. Simulation ranges from a simple queue to molecular dynamics, including seismic reliability analysis, structural integrity assessment, games, reliability engineering, and system safety. This book will introduce practitioners, researchers, and novice users to simulation and modeling, and to the world of imagination

Supply chain integration in the industry 4.0 era: a systematic literature review: Integração da cadeia de suprimentos na era industrial 4.0: uma revisão sistemática da literatura

From an Industry 4.0 perspective, supply chain actors (suppliers, manufacturers, retailers, and third-party logistics operators) are integrated into a collaborative network based on information-sharing to improve the overall supply chain performance. Real data can be captured and systematically processed into information, hence dealing with uncertainty. Poor integration may lead to supply chain disruptions. This paper examines the role of Industry 4.0 (I4.0) for integrating the supply chain, to which a systematic literature review (SLR) has been applied. First, according to the research questions, the I4.0 technologies adopted for supply chain integration were identified. Second, the approaches for integrating the supply chain at I4.0 were examined and classified by strategy (vertical, horizontal, and end-to-end integration). Third, the functional and cross-functional approaches for supply chain integration at I4.0 were also examined. Finally, it was discussed which traditional SCI approaches can be upgraded to the Industry 4.0 era and the future research directions

Fifth Workshop and Tutorial on Practical Use of Coloured Petri Nets and the CPN Tools Aarhus, Denmark, October 8-11, 2004

This booklet contains the proceedings of the Fifth Workshop on Practical Use of Coloured Petri Nets and the CPN Tools, October 8-11, 2004. The workshop is organised by the CPN group at the Department of Computer Science, University of Aarhus, Denmark. The papers are also available in electronic form via the web pages: http://www.daimi.au.dk/CPnets/workshop0