Automatic generation of human machine interface screens from component-based reconfigurable virtual manufacturing cell

Increasing complexity and decreasing time-tomarket require changes in the traditional way of building automation systems. The paper describes a novel approach to automatically generate the Human Machine Interface (HMI) screens for component-based manufacturing cells based on their corresponding virtual models. Manufacturing cells are first prototyped and commissioned within a virtual engineering environment to validate and optimise the control behaviour. A framework for reusing the embedded control information in the virtual models to automatically generate the HMI screens is proposed. Finally, for proof of concept, the proposed solution is implemented and tested on a test rig

Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

Web service control of component-based agile manufacturing systems

Current global business competition has resulted in significant challenges for manufacturing and production sectors focused on shorter product lifecyc1es, more diverse and customized products as well as cost pressures from competitors and customers. To remain competitive, manufacturers, particularly in automotive industry, require the next generation of manufacturing paradigms supporting flexible and reconfigurable production systems that allow quick system changeovers for various types of products. In addition, closer integration of shop floor and business systems is required as indicated by the research efforts in investigating "Agile and Collaborative Manufacturing Systems" in supporting the production unit throughout the manufacturing lifecycles. The integration of a business enterprise with its shop-floor and lifecycle supply partners is currently only achieved through complex proprietary solutions due to differences in technology, particularly between automation and business systems. The situation is further complicated by the diverse types of automation control devices employed. Recently, the emerging technology of Service Oriented Architecture's (SOA's) and Web Services (WS) has been demonstrated and proved successful in linking business applications. The adoption of this Web Services approach at the automation level, that would enable a seamless integration of business enterprise and a shop-floor system, is an active research topic within the automotive domain. If successful, reconfigurable automation systems formed by a network of collaborative autonomous and open control platform in distributed, loosely coupled manufacturing environment can be realized through a unifying platform of WS interfaces for devices communication. The adoption of SOA- Web Services on embedded automation devices can be achieved employing Device Profile for Web Services (DPWS) protocols which encapsulate device control functionality as provided services (e.g. device I/O operation, device state notification, device discovery) and business application interfaces into physical control components of machining automation. This novel approach supports the possibility of integrating pervasive enterprise applications through unifying Web Services interfaces and neutral Simple Object Access Protocol (SOAP) message communication between control systems and business applications over standard Ethernet-Local Area Networks (LAN's). In addition, the re-configurability of the automation system is enhanced via the utilisation of Web Services throughout an automated control, build, installation, test, maintenance and reuse system lifecycle via device self-discovery provided by the DPWS protocol...cont'd

A component-based virtual engineering approach to PLC code generation for automation systems

In recent years, the automotive industry has been significantly affected by a number of challenges driven by globalisation, economic fluctuations, environmental awareness and rapid technological developments. As a consequence, product lifecycles are shortening and customer demands are becoming more diverse. To survive in such a business environment, manufacturers are striving to find a costeffective solution for fast and efficient development and reconfiguration of manufacturing systems to satisfy the needs of changing markets without losses in production. Production systems within automotive industry are vastly automated and heavily rely on PLC-based control systems. It has been established that one of the major obstacles in realising reconfigurable manufacturing systems is the fragmented engineering approach to implement control systems. Control engineering starts at a very late stage in the overall system engineering process and remains highly isolated from the mechanical design and build of the system. During this stage, control code is typically written manually in vendor-specific tools in a combination of IEC 61131-3 languages. Writing control code is a complex, time consuming and error-prone process. [Continues.

Integration of sensor and actuator networks and the SCADA System to promote the migration of the legacy flexible manufacturing system towards the industry 4.0 concept

Se implementan redes de sensores y actuadores en los procesos de fabricación automatizados utilizando buses de campo industriales, donde las unidades de automatización y los sistemas de supervisión también están conectados a intercambiar información operacional. En el contexto de la cuarta revolución industrial entrante, llamada Industria 4.0, la gestión de las instalaciones de legado es una cuestión primordial a tratar. Este documento presenta una solución para mejorar la conectividad de un sistema de fabricación flexible heredado, que constituye el primer paso en la adopción del concepto de Industria 4.0. Tal sistema incluye el PROCESO de bus de campo FIELD BUS (PROFIBUS) alrededor del cual se interconectan los sensores, actuadores y controladores. En orden para establecer una comunicación efectiva entre la red de sensores y actuadores y una red de supervision se implementa un enfoque de hardware y software que incluye la conectividad Ethernet. Este se prevé que la labor contribuya a la migración de los sistemas heredados hacia la desafiante industria 4.0 marco. Los resultados experimentales prueban el correcto funcionamiento del FMS y la viabilidad de la propuesta.Networks of sensors and actuators in automated manufacturing processes are implemented using industrial fieldbuses, where automation units and supervisory systems are also connected to exchange operational information. In the context of the incoming fourth industrial revolution, called Industry 4.0, the management of legacy facilities is a paramount issue to deal with. This paper presents a solution to enhance the connectivity of a legacy Flexible Manufacturing System, which constitutes the first step in the adoption of the Industry 4.0 concept. Such a system includes the fieldbus PROcess FIeld BUS (PROFIBUS) around which sensors, actuators, and controllers are interconnected. In order to establish effective communication between the sensors and actuators network and a supervisory system, a hardware and software approach including Ethernet connectivity is implemented. This work is envisioned to contribute to the migration of legacy systems towards the challenging Industry 4.0 framework. The experimental results prove the proper operation of the FMS and the feasibility of the proposal.peerReviewe

Engineering methods and tools for cyber–physical automation systems

Much has been published about potential benefits of the adoption of cyber–physical systems (CPSs) in manufacturing industry. However, less has been said about how such automation systems might be effectively configured and supported through their lifecycles and how application modeling, visualization, and reuse of such systems might be best achieved. It is vitally important to be able to incorporate support for engineering best practice while at the same time exploiting the potential that CPS has to offer in an automation systems setting. This paper considers the industrial context for the engineering of CPS. It reviews engineering approaches that have been proposed or adopted to date including Industry 4.0 and provides examples of engineering methods and tools that are currently available. The paper then focuses on the CPS engineering toolset being developed by the Automation Systems Group (ASG) in the Warwick Manufacturing Group (WMG), University of Warwick, Coventry, U.K. and explains via an industrial case study how such a component-based engineering toolset can support an integrated approach to the virtual and physical engineering of automation systems through their lifecycle via a method that enables multiple vendors' equipment to be effectively integrated and provides support for the specification, validation, and use of such systems across the supply chain, e.g., between end users and system integrators