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

Model Petri Net untuk Otomatisasi Destilasi Bioethanol

– Petri net adalah satu di antara yang digunakan untuk pemodelan sistem otomatis. Tulisan ini melaporkan penggunaan model petri net pada purwarupa alat destilasi etanol otomatis, menggunakan PLC sebagai pengendali utama. Model proses mencakup perangkat keras dan lunak. Sistem pengaturan yang dimodelkan bertujuan menjaga agar suhu dalam wadah pemanas berada dalam kisaran titik didih etanol yaitu 80 ºC, serta pengamanan perangkat terutama terkait elemen pemanas. Pemodelan sistem pengaturan dikembangkan menggunakan petri net bebas, untuk implementasi pada PLC. Implementasi menghasilkan perangkat yang secara konsisten melakukan destilasi secara otomatis, dan menghasilkan cairan dengan kadar etanol 80% dari cairan awal berkadar 40%. Kata kunci – Petri net, PLC, destilasi, pengaturan suhu, pemana

Design and Simulation of a Supervisory Control System for Hybrid Manufacturing

The research teams of Dr. Bill Hamel, Dr. Bradley Jared and Dr. Tony Schmitz were tasked by the Office of Naval Research to create a hybrid manufacturing process for a reduced scale model of a naval ship propeller. The base structure of the propeller is created using Wire Arc Additive Manufacturing (WAAM), which is then scanned to compare created geometry to desired geometry. The propeller is then machined down to match the desired geometry. This process is iterated upon until the final product meets design tolerances. Due to the complex nature and numerous industrial machines used in the process, it is desirable to create a control system for Supervisory Control and Data Acquisition (SCADA). This supervisory control system is necessary in order to ensure safe operations and logging of system data to document successful trials. The goal of this thesis is to outline the design and simulation of a supervisory control system for this hybrid manufacturing cell. The design and implementation is focused on a simulation of the control of relevant boolean states of the system. This is accomplished through a Human Machine Interface (HMI) created in LabVIEW accompanied by appropriate data flow diagrams, models and communication specifications between machines. The creation of a digital twin of this hybrid manufacturing system was successful and useful in the implementation of physical components

Measuring the Overall Complexity of Graphical and Textual IEC 61131-3 Control Software

Software implements a significant proportion of functionality in factory automation. Thus, efficient development and the reuse of software parts, so-called units, enhance competitiveness. Thereby, complex control software units are more difficult to understand, leading to increased development, testing and maintenance costs. However, measuring complexity is challenging due to many different, subjective views on the topic. This paper compares different complexity definitions from literature and considers with a qualitative questionnaire study the complexity perception of domain experts, who confirm the importance of objective measures to compare complexity. The paper proposes a set of metrics that measure various classes of software complexity to identify the most complex software units as a prerequisite for refactoring. The metrics include complexity caused by size, data structure, control flow, information flow and lexical structure. Unlike most literature approaches, the metrics are compliant with graphical and textual languages from the IEC 61131-3 standard. Further, a concept for interpreting the metric results is presented. A comprehensive evaluation with industrial software from two German plant manufacturers validates the metrics' suitability to measure complexity.Comment: 8 pages, https://ieeexplore.ieee.org/abstract/document/9444196

Component-based control system development for agile manufacturing machine systems

It is now a common sense that manufactures including machine suppliers and system integrators of the 21 st century will need to compete on global marketplaces, which are frequently shifting and fragmenting, with new technologies continuously emerging. Future production machines and manufacturing systems need to offer the "agility" required in providing responsiveness to product changes and the ability to reconfigure. The primary aim for this research is to advance studies in machine control system design, in the context of the European project VIR-ENG - "Integrated Design, Simulation and Distributed Control of Agile Modular Machinery"

A Survey of Practical Formal Methods for Security

In today's world, critical infrastructure is often controlled by computing systems. This introduces new risks for cyber attacks, which can compromise the security and disrupt the functionality of these systems. It is therefore necessary to build such systems with strong guarantees of resiliency against cyber attacks. One way to achieve this level of assurance is using formal verification, which provides proofs of system compliance with desired cyber security properties. The use of Formal Methods (FM) in aspects of cyber security and safety-critical systems are reviewed in this article. We split FM into the three main classes: theorem proving, model checking, and lightweight FM. To allow the different uses of FM to be compared, we define a common set of terms. We further develop categories based on the type of computing system FM are applied in. Solutions in each class and category are presented, discussed, compared, and summarised. We describe historical highlights and developments and present a state-of-the-art review in the area of FM in cyber security. This review is presented from the point of view of FM practitioners and researchers, commenting on the trends in each of the classes and categories. This is achieved by considering all types of FM, several types of security and safety-critical systems, and by structuring the taxonomy accordingly. The article hence provides a comprehensive overview of FM and techniques available to system designers of security-critical systems, simplifying the process of choosing the right tool for the task. The article concludes by summarising the discussion of the review, focusing on best practices, challenges, general future trends, and directions of research within this field

Worker-robot cooperation and integration into the manufacturing workcell via the holonic control architecture

Cooperative manufacturing is a new field of research, which addresses new challenges beyond the physical safety of the worker. Those new challenges appear due to the need to connect the worker and the cobot from the informatics point of view in one cooperative workcell. This requires developing an appropriate manufacturing control system, which fits the nature of both the worker and the cobot. Furthermore, the manufacturing control system must be able to understand the production variations, to guide the cooperation between worker and the cobot and adapt with the production variations.Die kooperative Fertigung ist ein neues Forschungsgebiet, das sich neuen Herausforderungen stellt. Diese neuen Herausforderungen ergeben sich aus der Notwendigkeit, den Arbeiter und den Cobot aus der Sicht der Informatik in einem kooperativen Arbeitsplatz zu verbinden. Dies erfordert die Entwicklung eines geeigneten Produktionskontrollsystems, das sowohl der Natur des Arbeiters als auch der des Cobots entspricht. Darüber hinaus muss die Fertigungssteuerung in der Lage sein, die Produktionsschwankungen zu verstehen, um die Zusammenarbeit zwischen Arbeiter und Cobot zu steuern

A Capacity Planning Simulation Model for Reconfigurable Manufacturing Systems

Important objectives and challenges in today’s manufacturing environment include the introduction of new products and the designing and developing of reconfigurable manufacturing systems. The objective of this research is to investigate and support the reconfigurability of a manufacturing system in terms of scalability by applying a discrete-event simulation modelling technique integrated with flexible capacity control functions and communication rules for re-scaling process. Moreover, the possible extension of integrating the discrete-event simulation with an agent-based model is presented as a framework. The benefits of this framework are collaborative decision making using agents for flexible reaction to system changes and system performance improvement. AnyLogic multi-method simulation modelling platform is utilized to design and create different simulation modelling scenarios. The developed capacity planning simulation model results are demonstrated in terms of a case study using the configurable assembly Learning Factory (iFactory) in the Intelligent Manufacturing Systems (IMS) Center at the University of Windsor. The main benefit of developed capacity planning simulation in comparison to traditional discrete-event simulation is, with a single simulation run, the recommended capacity for manufacturing system will be determined instead of running several discrete-event simulation models to find the needed capacity

The Design and Implementation of Bloqqi - A Feature-Based Diagram Programming Language

This dissertation presents the design and implementation of a new block diagram programming language, Bloqqi, for building control systems with focus on variability. The language has been developed in collaboration with industry with the goal of reducing engineering time and improving reuse of functionality.When building a control system for a plant, there are typically different variants of the same base functionality. A plant may have several variants of a tank, for example, one variant with heating and another one without. This dissertation presents novel language mechanisms for describing this kind of variability, based on diagram inheritance. For instance, Bloqqi supports specifying what features, like heating, the base functionality can have. These specifications are then used to automatically derive smart-editing support in the form of a feature-based wizard. In this wizard, the user can select what features the base functionality should have, and code is generated corresponding to these features. The new language mechanisms allow feature-based libraries to be created and extended in a modular way.This dissertation presents techniques for implementing rich graphical editors with smart editing support based on semantic analysis. A prototype compiler and graphical editor have been implemented for the language, using the semantic formalism reference attribute grammars (RAGs). RAGs allow tools to share the semantic specifications, which makes it possible to modularly extend the compiler with support for advanced semantic feedback to the user of the graphical editor

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