Reconfigurable conveyor transfer system using IEC-61499 function blocks

Mestrado de dupla diplomação com o Centro Federal de Educação Tecnológica de Minas Gerais – CEFET-MGIn the 4th Industrial Revolution era, automation processes operate in a more modular, flexible, and reconfigurable manner, leveraging decentralized decision-making and distributed control. As the backbone of this revolution lies the Cyber-physical Production System (CPPS) concept, which emphasizes the strong interlink and interdependence of the digital/cyber and physical components. It requires the use of a technology capable of incorporating intelligence through the entities in a decentralized manner. IEC-61499 Function Blocks technology stands out as a suitable approach to implementing distributed automation control systems. This work presents the development of a dynamic and on-the-fly reconfiguration conveyor transfer system based on the IEC-61499 standard, that automatically adapts its operation to face changes in the number and position of the conveyor modules. For this purpose, the developed control system considers a Python-based Function Block (FB) network using the DINASORE framework, capable of effectively communicating between system components and identifying changes in real time. The experimental tests showed promising results regarding the system’s ability to adapt to condition changes automatically and on the fly, as well as its scalability and robustness.Na era da 4ª Revolução Industrial, os processos de automação operam de maneira mais modular, flexível e reconfigurável, aproveitando a tomada de decisão descentralizada e o controle distribuído. O conceito de Sistemas de Produção Cíber Físicos (do inglês Cyber-physical Production System - CPPS) surge como o principal componente dessa revolução, enfatizando a forte interligação e interdependência dos componentes digitais/cibernéticos e físicos, exigindo o uso de uma tecnologia capaz de incorporar inteligência por meio das entidades de forma descentralizada. A tecnologia de Function Blocks baseados na norma IEC-61499 destaca-se como uma abordagem adequada para implementar sistemas de controle de automação distribuídos. Este trabalho apresenta o desenvolvimento de um sistema dinâmico de transferência de esteira transportadora e de reconfiguração baseado na norma IEC-61499, adaptando automaticamente sua operação para enfrentar mudanças no número e na posição dos módulos da esteira. Para isso, o sistema de controle desenvolvido considera uma rede de FB baseada em Python usando o DINASORE, capaz de se comunicar efetivamente entre os componentes do sistema e identificar alterações em tempo real. Os testes experimentais mostraram resultados promissores com relação à capacidade do sistema de se adaptar às mudanças automaticamente e em tempo real, bem como sua escalabilidade e robustez

Internet of Things Software Modules Marketplace

The project developed is a centralised repository of software packages to be used in cyber-physical systems. It is composed by a central database, an http api, an ftp client to serve files and a web application to manage the repository. The system also communicates via OPCUA protocol with the embed-system for real time monitoring.The advent of the Cyber-Physical Systems (CPS), a physical system representation through a vir-tual model, usually used to control a system or a process comes from the growing democratizationof the computational power. Nowadays, virtually anything can be equipped with some kind ofembedded processor to automate tasks, generate or consume some kind of data. In addition, thecontinuous development and improvement of the communication networks has helped leveragethe concept of the Internet of Things (IoT) in which things are now, themselves, connected to theInternet, exchanging data with each other and with people.In the industrial sector, CPS, also called Cyber-Physical Production Systems (CPPS) and theIoT are the main technological advances that lead to the industry fourth revolution, common des-ignated as Industry 4.0 in which the factory floor is no longer a centralized model where all thecomputation is done centrally but is now a decentralized model where industrial equipment haveembedded devices to control, automate tasks and react in a dynamic and intelligent manner to thesensed physical environment.Thereby, one of the keywords around the CPPSs is software. Software is no longer centralizedand is now distributed through several devices that comprises the system. This new approachcomes with significant changes and one of them is the reuse and distribution of the software. Itis not viable to manual deploy and install software in hundreds or thousands of devices and nothaving a way of reusing the existing software. If, on the one hand, the desire is to develop a moreintelligent process control system, on the other, flexibility, adaptability and simplicity are alsoconvenient capabilities or else intelligent manufacturing process control systems are built upon alot of resources debt. Hence, the solution is to build standards, tools and frameworks that allowthe reuse of software and its rapid deployment in the distributed devices.One option, in the Industry 4.0 field, to cope with the software reuse issue in this kind of sys-tems is the encapsulation of software in functional blocks, the Function Blocks (FBs) and their usein the function block programming paradigm, described in IEC 61499 standard. The functionalityis abstracted away in the FBs and can be reused by just deploying the them to the devices. Thisway, it is easier to manage a network by dragging and dropping these blocks, building complexapplications centrally and deploy everything to the distributed embedded devices. However, theimplementation of this standard to address the aforementioned problem brings, itself, other neces-sities such as managing the FBs, monitoring them and their previous download by the embeddeddevices.This dissertation main goal is the development of a marketplace to manage and monitor of FBs in a IEC 61499 network envisioning the filling of the previous mentioned gaps in this kindof networks. The marketplace, integrated in a IEC 61499 global solution will not only enable thedistribution of FBs among the embedded devices in a IEC 61499 compliant CPPS but also manageFBs versions, functioning as a central repository of software components, having also monitoringand statistical features, allowing the detection of flaws or malfunctions and collect statistical datai iiabout FBs usage

Plataforma de gestión para aplicaciones IIoT con requisitos de calidad de servicio

El contenido de los capítulos 3, 4, 5 y 6 está sujeto a confidencialidad. 82 p.La Internet Industrial de las Cosas (IIoT) plantea una serie de retos tecnológicos que suponen la motivación de esta tesis. Por una parte es necesario gestionar aplicaciones geográficamente distribuidas y muy heterogéneas en cuanto a plataformas hardware, redes y protocolos de comunicación. Por otra parte, la naturaleza de las aplicaciones es intrínsecamente dinámica, y por tanto requiere de soporte para la reconfiguración dinámica y autónoma de los sistemas. Finalmente, existen una serie de requisitos no funcionales que son claves desde un enfoque industrial y que contemplan aspectos tales como la calidad de servicio, la tolerancia a fallos o la seguridad funcional.En este contexto, desde la perspectiva de la ingeniería del software y con el objetivo de facilitar el desarrollo y soporte de aplicaciones IIoT, se ha concebido una plataforma de gestión de aplicaciones distribuidas basadas en componentes, que soporta la reconfiguración dinámica y autónoma de las mismas en base a criterios de optimización de los recursos y de calidad de servicio. La plataforma soporta una serie de paradigmas de comunicación y modelos de ejecución que abarcan una amplia tipología de aplicaciones. Para su validación, se ha diseñado y desarrollado un demostrador en el campo de los almacenes automatizados

Plataforma de gestión para aplicaciones IIoT con requisitos de calidad de servicio

El contenido de los capítulos 3, 4, 5 y 6 está sujeto a confidencialidad. 82 p.La Internet Industrial de las Cosas (IIoT) plantea una serie de retos tecnológicos que suponen la motivación de esta tesis. Por una parte es necesario gestionar aplicaciones geográficamente distribuidas y muy heterogéneas en cuanto a plataformas hardware, redes y protocolos de comunicación. Por otra parte, la naturaleza de las aplicaciones es intrínsecamente dinámica, y por tanto requiere de soporte para la reconfiguración dinámica y autónoma de los sistemas. Finalmente, existen una serie de requisitos no funcionales que son claves desde un enfoque industrial y que contemplan aspectos tales como la calidad de servicio, la tolerancia a fallos o la seguridad funcional.En este contexto, desde la perspectiva de la ingeniería del software y con el objetivo de facilitar el desarrollo y soporte de aplicaciones IIoT, se ha concebido una plataforma de gestión de aplicaciones distribuidas basadas en componentes, que soporta la reconfiguración dinámica y autónoma de las mismas en base a criterios de optimización de los recursos y de calidad de servicio. La plataforma soporta una serie de paradigmas de comunicación y modelos de ejecución que abarcan una amplia tipología de aplicaciones. Para su validación, se ha diseñado y desarrollado un demostrador en el campo de los almacenes automatizados

A Diagnostics Model for Industrial Communications Networks

Over the past twenty years industrial communications networks have become common place in most industrial plants. The high availability of these networks is crucial in smooth plant operations. Therefore local and remote diagnostics of these networks is of primary importance in solving any existing or emerging network problems. Users for most part consider the “plant networks” as black boxes, and often not sure of the actual health of the networks. The major part of the work outlined in this research concentrates on the proposed “Network Diagnostics Model” for local and remote monitoring. The main objective of the research is to aid the establishment of tools and techniques for diagnosis of the industrial networks, with particular emphasis on PROFIBUS and PROFINET. Additionally this research has resulted in development of a number of devices to aid in network diagnostics. The work outlined in this submission contributes to the developments in the area of online diagnostics systems. The development work was conducted in the following phases: 1. Development of Function Block (FB) for diagnosing PROFIBUS network for implementation on PLC. 2. Development of OPC server for diagnosing PROFIBUS network for implementation on PC. 3. Development of a web based diagnostic software for multiple fieldbuses for implementation on imbedded XP platform. 4. Development of OPC server for diagnosing PROFINET network for implementation on PC 5. Conformance testing of masters (PLC) in PROFIBUS network to increase the health of the network. 6. Use of diagnostics tools for performance analysis of fieldbuses networks for high performance applications. The research work outlined in this submission has made a significant and coherent contribution to online diagnostics of fieldbus communications networks, and has paved the way for the introduction of the online diagnostics devices to the market place. It has shown that the proposed model provides a uniform framework for research and development of diagnostics tools and techniques for fieldbus networks. Organizations that use fieldbus should consider installing advanced online diagnostic systems to boost maintenance efficiency and reduce operating costs, and maintain the availability of plant resources. Based on the experience gained over a number of years a multilayer model is proposed for future development of diagnostics tools

Service-oriented architecture for device lifecycle support in industrial automation

Dissertação para obtenção do Grau de Doutor em Engenharia Electrotécnica e de Computadores Especialidade: Robótica e Manufactura IntegradaThis thesis addresses the device lifecycle support thematic in the scope of service oriented industrial automation domain. This domain is known for its plethora of heterogeneous equipment encompassing distinct functions, form factors, network interfaces, or I/O specifications supported by dissimilar software and hardware platforms. There is then an evident and crescent need to take every device into account and improve the agility performance during setup, control, management, monitoring and diagnosis phases. Service-oriented Architecture (SOA) paradigm is currently a widely endorsed approach for both business and enterprise systems integration. SOA concepts and technology are continuously spreading along the layers of the enterprise organization envisioning a unified interoperability solution. SOA promotes discoverability, loose coupling, abstraction, autonomy and composition of services relying on open web standards – features that can provide an important contribution to the industrial automation domain. The present work seized industrial automation device level requirements, constraints and needs to determine how and where can SOA be employed to solve some of the existent difficulties. Supported by these outcomes, a reference architecture shaped by distributed, adaptive and composable modules is proposed. This architecture will assist and ease the role of systems integrators during reengineering-related interventions throughout system lifecycle. In a converging direction, the present work also proposes a serviceoriented device model to support previous architecture vision and goals by including embedded added-value in terms of service-oriented peer-to-peer discovery and identification, configuration, management, as well as agile customization of device resources. In this context, the implementation and validation work proved not simply the feasibility and fitness of the proposed solution to two distinct test-benches but also its relevance to the expanding domain of SOA applications to support device lifecycle in the industrial automation domain