Collective intelligence in self-organized industrial cyber-physical systems

Cyber-physical systems (CPS) play an important role in the implementation of new Industry 4.0 solutions, acting as the backbone infrastructure to host distributed intelligence capabilities and promote the collective intelligence that emerges from the interactions among individuals. This collective intelligence concept provides an alternative way to design complex systems with several benefits, such as modularity, flexibility, robustness, and reconfigurability to condition changes, but it also presents several challenges to be managed (e.g., non-linearity, self-organization, and myopia). With this in mind, this paper discusses the factors that characterize collective intelligence, particularly that associated with industrial CPS, analyzing the enabling concepts, technologies, and application sectors, and providing an illustrative example of its application in an automotive assembly line. The main contribution of the paper focuses on a comprehensive review and analysis of the main aspects, challenges, and research opportunities to be considered for implementing collective intelligence in industrial CPS. The identified challenges are clustered according to five different categories, namely decentralization, emergency, intelligent machines and products, infrastructures and methods, and human integration and ethics. Although the research indicates some potential benefits of using collective intelligence to achieve the desired levels of autonomy and dynamic adaptation of industrial CPS, such approaches are still in the early stages, with perspectives to increase in the coming years. Based on that, they need to be further developed considering some main aspects, for example, related to balancing the distribution of intelligence by the vertical and horizontal dimensions and controlling the nervousness in self-organized systems.info:eu-repo/semantics/publishedVersio

Design of a Control System for a Reconfigurable Engine Assembly Line

Today’s automotive manufacturing environment is dynamic. It is characterized by short life cycles of products especially in powertrain, due in part to changing Government regulations for fuel economy. In the USA, the National Highway Traffic and Safety Administration (NHTSA), Corporate Average Fuel Economy (CAFE) mandates an average of 29 miles per gallon (mpg), gradually increasing to 35.5 mpg by 2016 and 54.5 mpg towards 2025. Life cycles of engines and transmissions have consequently shortened, driving automakers to develop and manufacture more efficient powertrains. Not long ago, plants produced engines for decades, with minor modifications warranting slight manufacturing line rework. Conversely, today’s changing trends require machines and complete engine line overhauls rendering initial setups obsolete. Automakers compete to satisfy government regulations for best mileage and also lower manufacturing cost, thus the adoption of Reconfigurable Manufacturing Systems (RMS). Production lines follow modularity in designs, for hardware and software, to adapt to new business conditions, economically and time-wise. Information Technology (IT) and Controls are growing closer with the line of demarcation disappearing in manufacturing. Controls are benefiting from opportunities in IT, hardware and software. The advent of agent-based technology which are autonomous, cooperative and extendible in different production activities, helped to develop controls for RMS in academia. Component-based software suitable for RMS modularity and plug-and-play hardware/software components has gained decades of popularity in the software industry. This thesis implements distributed controls imbedding component-based technology and IEC 61311-3 function block standard for automotive engine assembly, which will contribute to these developments. The control architecture provides reconfigurability which is lacking in current manufacturing systems. The research imbeds: 1- Reconfigurability - Fitting RMS-designed hardware towards new manufacturing, 2- Reusability - Building software library for reuse across assembly lines, and 3- Plug-and-Play - Embedding easy to assemble software components (function blocks)

Evaluation of C# for a station controller in a reconfigurable manufacturing system

Thesis (MEng)--Stellenbosch University, 2016.ENGLISH ABSTRACT: Reconfigurable manufacturing systems (RMSs) are aimed at dynamic situations, such as varying products, variations in production volume requirements and changes in available resources. RMSs distinguish themselves from other types of manufacturing systems in that they can quickly adapt to a new product being introduced without the need for long reconfiguration times, and can therefore cost effectively produce smaller batch sizes. RMSs in research environments in most cases used Agent Based Control (ABC), but the main automation vendors in the industry do not support ABC. This inhibits the acceptance of RMSs by the industry. For this research, C# was investigated as an alternative to ABC, since C# can provide for many of the functionalities of agents, yet is a more widely known language than ABC. Furthermore, C# is an object-oriented programming (OOP) language and thus possesses characteristics aligned with the core characteristics of reconfigurable manufacturing systems. The focus of this thesis is to determine the suitability of C# for the development of the control software for RMSs. This thesis describes the design, implementation, testing and evaluation of a reconfigurable stacking and buffering station. The controller was implemented in C# and made use of the ADACOR architecture. The physical test-setup was built to evaluate the reconfigurability of the controller in a series of reconfiguration experiments. The thesis showed that the controller could handle all the hardware interfaces without problems, since C# generally simplifies the task of hardware interfacing. OOP characteristics helped making developing and maintaining the code an intuitive task. The stacking station handled all communication with the cell controller correctly, which proved that it could easily be integrated into a distributed control architecture.AFRIKAANSE OPSOMMING: "Reconfigurable manufacturing systems" (RMSs) is gemik op dinamiese situasies, soos veranderende produkte, veranderings in produksievolumes en veranderinge in beskikbare hulpbronne. RMSs onderskei hulself van ander tipes vervaardigingstelsels deurdat hulle vinnig kan aanpas by nuwe produkte wat bekendgestel word sonder dat dit nodig is om die stelsel eers lank te herkonfigureer, en kan sodoende kleiner lotgroottes koste-effektief produseer. RMSs maak in navorsingmilieus meestal gebruik van "Agent Based Control" (ABC), maar die hoof outomatisasie-verkopers in die industrie ondersteun nie ABC nie. Dit belemmer die aanvaarding van RMSs in die industrie. Vir hierdie navorsing is C# as 'n alternatief vir ABC ondersoek omdat C# baie van die funksionaliteite kan voorsien wat aangetref word in ABC, maar terselfdertyd 'n meer bekende taal is as ABC. Verder is C# 'n objek-georiënteerde programmerings- (OOP) taal en beskik dus oor karakteristieke wat in lyn is met die kernkarakteristieke van RMSs. Die fokus van hierdie tesis is die geskiktheid van C# vir die ontwikkeling van beheersagteware vir 'n RMS. Hierdie tesis beskryf die ontwerp, implementering, toetsing en evaluering van 'n herkonfigureerbare stapel- en bufferstasie. Die beheerder was in C# geïmplementeer en het van die ADACOR-argitektuur gebruik gemaak. Die fisiese toets-opstelling was gebou om die herkonfigureerbaarheid van die beheerder te kan evalueer aan hand van 'n reeks herkonfigureringseksperimente. Die tesis het gewys dat die beheerder sonder probleme alle hardeware-intervlakke kon hanteer, omdat C# dit oor die algemeen vergemaklik om met hardeware te kommunikeer. OOP karakteristieke was nuttig om die ontwikkeling en instandhouding van die program intuïtief te maak. Die stapelstasie het alle kommunikasie met die selbeheerder korrek hanteer, wat bewys het dat dit probleemloos in 'n verspreide beheerargitektuur opgeneem kon word

A holonic manufacturing architecture for line-less mobile assembly systems operations planning and control

Dissertação (mestrado) - Universidade Federal de Santa Catarina, Centro Tecnológico, Programa de Pós-Graduação em Engenharia de Automação e Sistemas, Florianópolis, 2022.O Line-Less Mobile Assembly Systems (LMAS) é um paradigma de fabricação que visa maximizar a resposta às tendências do mercado através de configurações adaptáveis de fábrica utilizando recursos de montagem móvel. Tais sistemas podem ser caracterizados como holonic manufacturing systems (HMS), cujas chamadas holonic control architecture (HCA) são recentemente retratadas como abordagens habilitadoras da Indústria 4.0 devido a suas relações de entidades temporárias (hierárquicas e/ou heterárquicas). Embora as estruturas de referência HCA como PROSA ou ADACOR/ADACOR² tenham sido muito discutidas na literatura, nenhuma delas pode ser aplicada diretamente ao contexto LMAS. Assim, esta dissertação visa responder à pergunta \"Como uma arquitetura de produção e sistema de controle LMAS precisa ser projetada?\" apresentando os modelos de projeto de arquitetura desenvolvidos de acordo com as etapas da metodologia para desenvolvimento de sistemas holônicos multi-agentes ANEMONA. A fase de análise da ANEMONA resulta em uma especificação do caso de uso, requisitos, objetivos do sistema, simplificações e suposições. A fase de projeto resulta nos modelos de organização, interação e agentes, seguido de uma breve análise de sua cobertura comportamental. O resultado da fase de implementação é um protótipo (realizado com o Robot Operation System) que implementa os modelos ANEMONA e uma ontologia LMAS, que reutiliza elementos de ontologias de referência do domínio de manufatura. A fim de testar o protótipo, um algoritmo para geração de dados para teste baseado na complexidade dos produtos e na flexibilidade do chão de fábrica é apresentado. A validação qualitativa dos modelos HCA é baseada em como o HCA proposto atende a critérios específicos para avaliar sistemas HCA. A validação é complementada por uma análise quantitativa considerando o comportamento dos modelos implementados durante a execução normal e a execução interrompida (e.g. equipamento defeituoso) em um ambiente simulado. A validação da execução normal concentra-se no desvio de tempo entre as agendas planejadas e executadas, o que provou ser em média irrelevante dentro do caso simulado considerando a ordem de magnitude das operações típicas demandadas. Posteriormente, durante a execução do caso interrompido, o sistema é testado sob a simulação de uma falha, onde duas estratégias são aplicadas, LOCAL\_FIX e REORGANIZATION, e seu resultado é comparado para decidir qual é a opção apropriada quando o objetivo é reduzir o tempo total de execução. Finalmente, é apresentada uma análise sobre a cobertura desta dissertação culminando em diretrizes que podem ser vistas como uma resposta possível (entre muitas outras) para a questão de pesquisa apresentada. Além disso, são apresentados pontos fortes e fracos dos modelos desenvolvidos, e possíveis melhorias e idéias para futuras contribuições para a implementação de sistemas de controle holônico para LMAS.Abstract: The Line-Less Mobile Assembly Systems (LMAS) is a manufacturing paradigm aiming to maximize responsiveness to market trends (product-individualization and ever-shortening product lifecycles) by adaptive factory configurations utilizing mobile assembly resources. Such responsive systems can be characterized as holonic manufacturing systems (HMS), whose so-called holonic control architectures (HCA) are recently portrayed as Industry 4.0-enabling approaches due to their mixed-hierarchical and -heterarchical temporary entity relationships. They are particularly suitable for distributed and flexible systems as the Line-Less Mobile Assembly or Matrix-Production, as they meet reconfigurability capabilities. Though HCA reference structures as PROSA or ADACOR/ADACOR² have been heavily discussed in the literature, neither can directly be applied to the LMAS context. Methodologies such as ANEMONA provide guidelines and best practices for the development of holonic multi-agent systems. Accordingly, this dissertation aims to answer the question \"How does an LMAS production and control system architecture need to be designed?\" presenting the architecture design models developed according to the steps of the ANEMONA methodology. The ANEMONA analysis phase results in a use case specification, requirements, system goals, simplifications, and assumptions. The design phase results in an LMAS architecture design consisting of the organization, interaction, and agent models followed by a brief analysis of its behavioral coverage. The implementation phase result is an LMAS ontology, which reuses elements from the widespread manufacturing domain ontologies MAnufacturing's Semantics Ontology (MASON) and Manufacturing Resource Capability Ontology (MaRCO) enriched with essential holonic concepts. The architecture approach and ontology are implemented using the Robot Operating System (ROS) robotic framework. In order to create test data sets validation, an algorithm for test generation based on the complexity of products and the shopfloor flexibility is presented considering a maximum number of operations per work station and the maximum number of simultaneous stations. The validation phase presents a two-folded validation: qualitative and quantitative. The qualitative validation of the HCA models is based on how the proposed HCA attends specific criteria for evaluating HCA systems (e.g., modularity, integrability, diagnosability, fault tolerance, distributability, developer training requirements). The validation is complemented by a quantitative analysis considering the behavior of the implemented models during the normal execution and disrupted execution (e.g.; defective equipment) in a simulated environment (in the form of a software prototype). The normal execution validation focuses on the time drift between the planned and executed schedules, which has proved to be irrelevant within the simulated case considering the order of magnitude of the typical demanded operations. Subsequently, during the disrupted case execution, the system is tested under the simulation of a failure, where two strategies are applied, LOCAL\_FIX and REORGANIZATION, and their outcome is compared to decide which one is the appropriate option when the goal is to reduce the overall execution time. Ultimately, it is presented an analysis about the coverage of this dissertation culminating into guidelines that can be seen as one possible answer (among many others) for the presented research question. Furthermore, strong and weak points of the developed models are presented, and possible improvements and ideas for future contributions towards the implementation of holonic control systems for LMAS

Agents enabling cyber-physical production systems

In order to be prepared for future challenges facing the industrial production domain, Cyber-Physical Production Systems (CPPS) consisting of intelligent entities which collaborate and exchange information globally are being proclaimed recently as part of Industrie 4.0. In this article the requirements of CPPS and abilities of agents as enabling technology are discussed. The applicability of agents for realizing CPPS is exemplarily shown based on three selected use cases with different requirements regarding real-time and dependability. The paper finally concludes with opportunities and open research issues that need to be faced in order to achieve agent-based CPPSs.info:eu-repo/semantics/publishedVersio

Evaluation of control systems for automated aircraft wing manufacturing

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics; in conjunction with the Leaders for Global Operations Program at MIT, 2013.This electronic version was submitted and approved by the author's academic department as part of an electronic thesis pilot project. The certified thesis is available in the Institute Archives and Special Collections.Cataloged from department-submitted PDF version of thesisIncludes bibliographical references (p. 62-64).The Boeing Company is looking to bring aircraft manufacturing technology into the 21st century. As part of this process, several projects have been started to develop the technologies required to achieve Boeing's vision for the future of aircraft manufacturing. To date, much of this work has focused on hardware, including robotic and other automation technologies. However, in order to use this hardware, a significant effort must also be made in the area of factory control and coordination. This thesis advances knowledge in this area by evaluating the suitability of different control system approaches for aircraft wing box assembly. First, general classes of control systems are discussed and several criteria are proposed for evaluating their performance in an aircraft manufacturing environment. The current wing box assembly process is then examined in order to develop simplified but representative task networks to which various algorithms can be applied. The Tercio algorithm, developed at MIT, is used to generate schedules for several problem structures of interest in order to characterize the algorithm's performance in this context. The Tercio algorithm is then benchmarked against the Aurora scheduling tool, showing that Tercio can generate more efficient schedules than Aurora, but at the cost of increased computation time. Next, management considerations with respect to product design, manufacturing technology development, and implementation associated with advanced manufacturing technologies are discussed. Finally, recommendations are provided for how Boeing can accelerate the development of useful and practical advanced, automated manufacturing systems.by Jason Herrera.S.M.M.B.A

Capability-based adaptation of production systems in a changing environment

Today’s production systems have to cope with volatile production environments characterized by frequently changing customer requirements, an increasing number of product variants, small batch sizes, short product life-cycles, the rapid emergence of new technical solutions and increasing regulatory requirements aimed at sustainable manufacturing. These constantly changing requirements call for adaptive and rapidly responding production systems that can adjust to the required changes in processing functions, production capacity and the distribution of the orders. This adaptation is required on the physical, logical and parametric levels. Such adaptivity cannot be achieved without intelligent methodologies, information models and tools to facilitate the adaptation planning and reactive adaptation of the systems. In industry it has been recognized that, because of the often expensive and inefficient adaptation process, companies rarely decide to adapt their production lines. This is mainly due to a lack of sufficient information and documentation about the capabilities of the current system and its lifecycle, as well as a lack of detailed methods for planning the adaptation, which makes it impossible to accurately estimate its scale and cost. Currently, the adaptation of production systems is in practice a human driven process, which relies strongly on the expertise and tacit knowledge of the system integrators or the end-user of the system. This thesis develops a capability-based, computer-aided adaptation methodology, which supports both the human-controlled adaptation planning and the dynamic reactive adaptation of production systems. The methodology consists of three main elements. The first element is the adaptation schema, which illustrates the activities and information flows involved in the overall adaptation planning process and the resources used to support the planning. The adaptation schema forms the backbone of the methodology, guiding the use of other developed elements during both the adaptation planning and reactive adaptation. The second element, which is actually the core of the developed methodology, is the formal ontological resource description used to describe the resources based on their capabilities. The overall resource description utilizes a capability model, which divides the capabilities into simple and combined capabilities. The resources are assigned the simple capabilities they possess. When multiple resources are co-operating, their combined capability can be reasoned out based on the associations defined in the capability model. The adaptation methodology is based on the capability-based matching of product requirements and available system capabilities in the context of the adaptation process. Thus, the third main element developed in this thesis is the framework and rules for performing this capability matching. The approach allows automatic information filtering and the generation of system configuration scenarios for the given requirements, thus facilitating the rapid allocation of resources and the adaptation of systems. Human intelligence is used to validate the automatically-generated scenarios and to select the best one, based on the desired criteria. Based on these results, an approach to evaluating the compatibility of an existing production system with different product requirements has been formulated. This approach evaluates the impact any changes in these requirements may have on the production system. The impact of the changes is illustrated in the form of compatibility graphs, which enable comparison between different product scenarios in terms of the effort required to implement the system adaptation, and the extent to which the current system can be utilized to meet the new requirements. It thus aids in making decisions regarding product and production strategies and adaptation

A new approach for the validation of conceptual holonic constructions

The concepts of holon and holarchy were first applied in the manufacturing world to develop Holonic Manufacturing Systems. Since then, they have been used in many fields and have proved to be applicable concepts for developing applications in any business area. Resulting applications are based on conceptual holonic constructions. Like any model, a holarchy needs to be validated under real circumstances. Such validation assures the quality of the holarchy before it is implemented. In general, validation research tends to target: 1) the specific types of holons handled in each proposal and/or the selected development paradigms; and 2) algorithm performance rather than architecture quality. This paper proposes and evaluates a methodology that focuses on the quality of the architecture. This methodology is able to validate any holonic architecture built to meet trade requirements. Moreover, this is a general-purpose methodology. Therefore, the methodology would be valid for any domain and would not be invalidated by holon types and/or implementation paradigms emerging, changing or falling into disuse. For this purpose, we consider holonic architectures as conceptual models, using the pure holon and holarchy concepts and passing up not only any specific implementation paradigm but also any set of specific holon types