358 research outputs found

    Model-Driven Design and Development of Flexible Automated Production Control Configurations for Industry 4.0

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    The continuous changes of the market and customer demands have forced modern automation systems to provide stricter Quality of service (QoS) requirements. This work is centered in automation production system flexibility, understood as the ability to shift from one controller configuration to a different one, in the most quick and cost-effective way, without disrupting its normal operation. In the manufacturing field, this allows to deal with non-functional requirements such as assuring control system availability or workload balancing, even in the case of failure of a machine, components, network or controllers. Concretely, this work focuses on flexible applications at production level, using Programmable Logic Controllers (PLCs) as primary controllers. The reconfiguration of the control system is not always possible as it depends on the process state. Thus, an analysis of the system state is necessary to make a decision. In this sense, architectures based on industrial Multi Agent Systems (MAS) have been used to provide this support at runtime. Additionally, the introduction of these mechanisms makes the design and the implementation of the control system more complex. This work aims at supporting the design and development of such flexible automation production systems, through the proposed model-based framework. The framework consists of a set of tools that, based on models, automate the generation of control code extensions that add flexibility to the automation production system, according to industry 4.0 paradigm.This work was financed by MCIU/AEI/FEDER, UE (grant number RTI2018-096116-B-I00) and by GV/EJ (grant number IT1324-19)

    Interaction of Mechatronic Modules in Distributed Technological Installations

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    The article deals with the interaction of mechatronic devices in real time through events and messages. The interaction of distributed network devices is necessary to coordinate their work, including synchronization when implementing a distributed algorithm. The approach in the development of a distributed control system (DCS) for mechatronic devices based on the IEC 61499 standard has been analyzed. Using only a LAN for interaction purposes is not always justified, since messages transmitted over a LAN do not provide transmission determinism. To eliminate this problem, a fast local network is needed, which would not utilize resources of the main computer and hardware (e.g., based on the model of terminal machines) to carry out a network communication. It is proposed to implement LAN controllers on the field-programmable gate array (FPGA) platform. Data-strobe coding (DS coding) with a signal level of LVDS was used for keeping the transmitted data intact and improving the overall reliability of the systems

    Low-cost Industrial controller based on the Raspberry Pi platform

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    Mestrado de dupla diplomação com o Centro Federal de Educação Tecnológica Celso Suckow da Fonseca - CEFET/RJThe low-cost automation field exhibits the need of innovation both in terms of hardware and software. There is a lack of devices that allow the development of control logic that is free from restrictions of domain-specific communication platforms and at the same time able to provide the capabilities aligned to the Industry 4.0 requirements. The objective of this work is to develop an inexpensive, small Industrial Controller that supports the execution of programs in different industrial programming languages. So, it is intended to develop, manufacture and control a low-cost but powerful Industrial Controller based on the use of the single-board computer Raspberry Pi. The study described in this document was carried out on the creation of a hardware platform that is capable of integrating with software frameworks compatible with standards updated and widely used in the industrial automation field. IEC 61131-3 is employed displaying the ease of use and implementation alongside multiple well established programming languages for automation through the OpenPLC platform while IEC 61449 is employed through the 4DIAC framework that has a clear and objective environment capable of providing the appropriate tools for implementation of a distributed control. It is employed the single-board computer Raspberry Pi, a robust device with adequate processing power and communication capability for the elaboration of a platform in the low-cost automation scope. The elaboration of the Industrial Shields, responsible for providing the controller I/O interface took into consideration maintenance concerns of controller integrity through the application of galvanic isolation in the automaton input and output sections. The proposed platform was successfully tested in an automation system prototype comprising Fischertechnik’s Punching Machine being possible to develop the control logic using IEC 61131-3 and IEC 61499.O campo de automação de baixo custo demonstra a necessidade de inovação em termos de hardware e software. Há uma falta de dispositivos que permitem o desenvolvimento de lógica de controle livre de restrições de plataformas de comunicação específicas de domínio e, ao mesmo tempo, capazes de fornecer os recursos alinhados aos requisitos da Indústria 4.0. O objetivo deste trabalho é desenvolver um pequeno Controlador Industrial de baixo custo que suporte a execução de programas em diferentes linguagens de programação industrial. Assim, pretende-se desenvolver, fabricar e controlar um Controlador Industrial de baixo custo, mas poderoso, baseado no uso do computador de placa única Raspberry Pi. O estudo descrito neste documento foi realizado na criação de uma plataforma de hardware que é capaz de se integrar com frameworks de software compatíveis com padrões atualizados e amplamente utilizados na área de automação industrial. A IEC 61131-3 é empregada exibindo a facilidade de uso e implementação juntamente com várias linguagens de programação bem estabelecidas para automação através da plataforma OpenPLC enquanto a IEC 61449 é empregada através da estrutura 4DIAC que possui um ambiente claro e objetivo capaz de fornecer as ferramentas apropriadas para implementação de um controle distribuído. É empregado o computador de placa única Raspberry Pi, um dispositivo robusto com capacidade de processamento e capacidade de comunicação adequados para a elaboração de uma plataforma no escopo de automação de baixo custo. A elaboração dos industrial shields, responsáveis por fornecer a interface de I/O do controlador levou em consideração as preocupações de manutenção da integridade do controlador através da aplicação de isolação galvânica nas seções de entrada e saída do autômato. A plataforma proposta foi testada com sucesso em um protótipo de sistema de automação compreendendo a Punching Machine da Fischertechnik sendo possível desenvolver a lógica de controle usando IEC 61131-3 e IEC 61499

    Customizable service-oriented Petri net controllers

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    In industrial automation, service-orientation is a relatively new and ascending concept and thus, concrete integrated methodologies are missing to accomplish the required development tasks. A suitable approach is to use the powerful set of features that Petri nets formalism provides for such dynamic systems. This paper presents a token game template that is part of the open methodology for the development of customized Petri nets controllers, targeting the engineering of service-oriented industrial automation. This template is based on a state machine specification for the life-cycle of transitions that leaves several options open for extending it with features depending on the application. The practical use and implementation should bring, among others, featured-full and integrated modeling, analysis and control capabilities, which is required by service-oriented ecosystems. This core structure was used and validated in the development of control applications for an industrial automation system.The authors would like to thank the European Commission and the partners of the EU IST FP6 project “Service-Oriented Cross-layer infrastructure for Distributed smart Embedded devices” (SOCRADES), the EU FP6 “Network of Excellence for Innovative Production Machines and Systems” (I*PROMS), and the European ICT FP7 project “Cooperating Objects Network of Excellence” (CONET) for their support

    Automatic translation from FBD-PLC-programs to NuSMV for model checking safety-critical control systems

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    Programmable logic controllers (PLCs) are digital control systems, commonly used in industrial automation and safety-critical applications. Control systems used in safety-critical areas must undergo an extensive and thorough certification and verification process. In safety-critical applications, the PLC programming standard IEC 61131-3 is widely accepted in industry. PLC programmers who develop control systems for safety-critical systems are often required to verify the logic of PLCs by using formal methods such as model checking. Translating manually from a PLC program to the input language of a model checker takes times and is often error-prone. We develop a compiler to automatically translate PLC programs in the function block diagram (FBD) language, one of five industry standard PLC programming notations, to the input language of the model checker NuSMV. We have evaluated correctness, robustness, and performance of the PLC-NuSMV compiler using a case study. Evaluation results show that the compiler can translate the PLC programs correctly. The compiler can also identify several input errors and can scale to relative large PLC programs

    HyPLC: Hybrid Programmable Logic Controller Program Translation for Verification

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    Programmable Logic Controllers (PLCs) provide a prominent choice of implementation platform for safety-critical industrial control systems. Formal verification provides ways of establishing correctness guarantees, which can be quite important for such safety-critical applications. But since PLC code does not include an analytic model of the system plant, their verification is limited to discrete properties. In this paper, we, thus, start the other way around with hybrid programs that include continuous plant models in addition to discrete control algorithms. Even deep correctness properties of hybrid programs can be formally verified in the theorem prover KeYmaera X that implements differential dynamic logic, dL, for hybrid programs. After verifying the hybrid program, we now present an approach for translating hybrid programs into PLC code. The new tool, HyPLC, implements this translation of discrete control code of verified hybrid program models to PLC controller code and, vice versa, the translation of existing PLC code into the discrete control actions for a hybrid program given an additional input of the continuous dynamics of the system to be verified. This approach allows for the generation of real controller code while preserving, by compilation, the correctness of a valid and verified hybrid program. PLCs are common cyber-physical interfaces for safety-critical industrial control applications, and HyPLC serves as a pragmatic tool for bridging formal verification of complex cyber-physical systems at the algorithmic level of hybrid programs with the execution layer of concrete PLC implementations.Comment: 13 pages, 9 figures. ICCPS 201
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