An approach to open virtual commissioning for component-based automation

Increasing market demands for highly customised products with shorter time-to-market and at lower prices are forcing manufacturing systems to be built and operated in a more efficient ways. In order to overcome some of the limitations in traditional methods of automation system engineering, this thesis focuses on the creation of a new approach to Virtual Commissioning (VC). In current VC approaches, virtual models are driven by pre-programmed PLC control software. These approaches are still time-consuming and heavily control expertise-reliant as the required programming and debugging activities are mainly performed by control engineers. Another current limitation is that virtual models validated during VC are difficult to reuse due to a lack of tool-independent data models. Therefore, in order to maximise the potential of VC, there is a need for new VC approaches and tools to address these limitations. The main contributions of this research are: (1) to develop a new approach and the related engineering tool functionality for directly deploying PLC control software based on component-based VC models and reusable components; and (2) to build tool-independent common data models for describing component-based virtual automation systems in order to enable data reusability. [Continues.

Industrial Applications: New Solutions for the New Era

This book reprints articles from the Special Issue "Industrial Applications: New Solutions for the New Age" published online in the open-access journal Machines (ISSN 2075-1702). This book consists of twelve published articles. This special edition belongs to the "Mechatronic and Intelligent Machines" section

An approach to resource modelling in support of the life cycle engineering of enterprise systems

Enterprise modelling can facilitate the design, analysis, control and construction of contemporary enterprises which can compete in world-wide Product markets. This research involves a systematic study of enterprise modelling with a particular focus on resource modelling in support of the life cycle engineering of enterprise systems. This led to the specification and design of a framework for resource modelling. This framework was conceived to: classify resource types; identify the different functions that resource modelling can support, with respect to different life phases of enterprise systems; clarify the relationship between resource models and other modelling perspectives provide mechanisms which link resource models and other types of models; identify guidelines for the capture of information - on resources, leading to the establishment of a set of resource reference models. The author also designed and implemented a resource modelling tool which conforms to the principles laid down by the framework. This tool realises important aspects of the resource modeffing concepts so defined. Furthermore, two case studies have been carried out. One models a metal cutting environment, and the other is based on an electronics industry problem area. In this way, the feasibility of concepts embodied in the framework and the design of the resource modelling tool has been tested and evaluated. Following a literature survey and preliminary investigation, the CIMOSA enterprise modelling and integration methodology was adopted and extended within this research. Here the resource modelling tool was built by extending SEWOSA (System Engineering Workbench for Open System Architecture) and utilising the CIMBIOSYS (CINI-Building Integrated Open SYStems) integrating infrastructure. The main contributions of the research are that: a framework for resource modelling has been established; means and mechanisms have been proposed, implemented and tested which link and coordinate different modelling perspectives into an unified enterprise model; the mechanisms and resource models generated by this research support each Pfe phase of systems engineering projects and demonstrate benefits by increasing the degree to which the derivation process among models is automated

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

A new approach to the development and maintenance of industrial sequence logic

This thesis is concerned with sequence logic as found in industrial control systems, with the focus being on process and manufacturing control systems. At its core is the assertion that there is a need for a better approach to the development of industrial sequence logic to satisfy the life-cycle requirements, and that many of the ingredients required to deliver such an approach are now available. The needs are discussed by considering the business case for automation and deficiencies with traditional approaches. A set of requirements is then derived for an integrated development environment to address the business needs throughout the control system life-cycle. The strengths and weaknesses of relevant control system technology and standards are reviewed and their bias towards implementation described. Mathematical models, graphical methods and software tools are then assessed with respect to the requirements for an integrated development environment. A solution to the requirements, called Synect is then introduced. Synect combines a methodology using familiar graphical notations with Petri net modelling supported by a set of software tools. Its key features are justified with reference to the requirements. A set of case studies forms the basis of an evaluation against business needs by comparing the Synect methodology with current approaches. The industrial relevance and exploitation are then briefly described. The thesis ends with a review of the key conclusions along with contributions to knowledge and suggestions for further research

Towards semantics-driven modelling and simulation of context-aware manufacturing systems

Systems modelling and simulation are two important facets for thoroughly and effectively analysing manufacturing processes. The ever-growing complexity of the latter, the increasing amount of knowledge, and the use of Semantic Web techniques adhering meaning to data have led researchers to explore and combine together methodologies by exploiting their best features with the purpose of supporting manufacturing system's modelling and simulation applications. In the past two decades, the use of ontologies has proven to be highly effective for context modelling and knowledge management. Nevertheless, they are not meant for any kind of model simulations. The latter, instead, can be achieved by using a well-known workflow-oriented mathematical modelling language such as Petri Net (PN), which brings in modelling and analytical features suitable for creating a digital copy of an industrial system (also known as "digital twin"). The theoretical framework presented in this dissertation aims to exploit W3C standards, such as Semantic Web Rule Language (SWRL) and Web Ontology Language (OWL), to transform each piece of knowledge regarding a manufacturing system into Petri Net modelling primitives. In so doing, it supports the semantics-driven instantiation, analysis and simulation of what we call semantically-enriched PN-based manufacturing system digital twins. The approach proposed by this exploratory research is therefore based on the exploitation of the best features introduced by state-of-the-art developments in W3C standards for Linked Data, such as OWL and SWRL, together with a multipurpose graphical and mathematical modelling tool known as Petri Net. The former is used for gathering, classifying and properly storing industrial data and therefore enhances our PN-based digital copy of an industrial system with advanced reasoning features. This makes both the system modelling and analysis phases more effective and, above all, paves the way towards a completely new field, where semantically-enriched PN-based manufacturing system digital twins represent one of the drivers of the digital transformation already in place in all companies facing the industrial revolution. As a result, it has been possible to outline a list of indications that will help future efforts in the application of complex digital twin support oriented solutions, which in turn is based on semantically-enriched manufacturing information systems. Through the application cases, five key topics have been tackled, namely: (i) semantic enrichment of industrial data using the most recent ontological models in order to enhance its value and enable new uses; (ii) context-awareness, or context-adaptiveness, aiming to enable the system to capture and use information about the context of operations; (iii) reusability, which is a core concept through which we want to emphasize the importance of reusing existing assets in some form within the industrial modelling process, such as industrial process knowledge, process data, system modelling primitives, and the like; (iv) the ultimate goal of semantic Interoperability, which can be accomplished by adding data about the metadata, linking each data element to a controlled, shared vocabulary; finally, (v) the impact on modelling and simulation applications, which shows how we could automate the translation process of industrial knowledge into a digital manufacturing system and empower it with quantitative and qualitative analytical technics

Foundations of Multi-Paradigm Modelling for Cyber-Physical Systems

This open access book coherently gathers well-founded information on the fundamentals of and formalisms for modelling cyber-physical systems (CPS). Highlighting the cross-disciplinary nature of CPS modelling, it also serves as a bridge for anyone entering CPS from related areas of computer science or engineering. Truly complex, engineered systems—known as cyber-physical systems—that integrate physical, software, and network aspects are now on the rise. However, there is no unifying theory nor systematic design methods, techniques or tools for these systems. Individual (mechanical, electrical, network or software) engineering disciplines only offer partial solutions. A technique known as Multi-Paradigm Modelling has recently emerged suggesting to model every part and aspect of a system explicitly, at the most appropriate level(s) of abstraction, using the most appropriate modelling formalism(s), and then weaving the results together to form a representation of the system. If properly applied, it enables, among other global aspects, performance analysis, exhaustive simulation, and verification. This book is the first systematic attempt to bring together these formalisms for anyone starting in the field of CPS who seeks solid modelling foundations and a comprehensive introduction to the distinct existing techniques that are multi-paradigmatic. Though chiefly intended for master and post-graduate level students in computer science and engineering, it can also be used as a reference text for practitioners

Road2CPS priorities and recommendations for research and innovation in cyber-physical systems

This document summarises the findings of the Road2CPS project, co-financed by the European Commission under the H2020 Research and Innovation Programme, to develop a roadmap and recommendations for strategic action required for future deployment of Cyber-Physical Systems (CPS). The term Cyber-Physical System describes hardware-software systems, which tightly couple the physical world and the virtual world. They are established from networked embedded systems that are connected with the outside world through sensors and actuators and have the capability to collaborate, adapt, and evolve. In the ARTEMIS Strategic Research Agenda 2016, CPS are described as ‘Embedded Intelligent ICT Systems’ that make products smarter, more interconnected, interdependent, collaborative, and autonomous. In the future world of CPS, a huge number of devices connected to the physical world will be able to exchange data with each other, access web services, and interact with people. Moreover, information systems will sense, monitor and even control the physical world via Cyber-Physical Systems and the Internet of Things (HiPEAC Vision 2015). Cyber-Physical Systems find their application in many highly relevant areas to our society: multi-modal transport, health, smart factories, smart grids and smart cities amongst others. The deployment of Cyber-Physical Systems (CPS) is expected to increase substantially over the next decades, holding great potential for novel applications and innovative product development. Digital technologies have already pervaded day-to-day life massively, affecting all kinds of interactions between humans and their environment. However, the inherent complexity of CPSs, as well as the need to meet optimised performance and comply with essential requirements like safety, privacy, security, raises many questions that are currently being explored by the research community. Road2CPS aims at accelerating uptake and implementation of these efforts. The Road2CPS project identifying and analysing the relevant technology fields and related research priorities to fuel the development of trustworthy CPS, as well as the specific technologies, needs and barriers for a successful implementation in different application domains and to derive recommendations for strategic action. The document at hand was established through an interactive, community-based approach, involving over 300 experts from academia, industry and policy making through a series of workshops and consultations. Visions and priorities of recently produced roadmaps in the area of CPS, IoT (Internet of Things), SoS (System-of-Systems) and FoF (Factories of the Future) were discussed, complemented by sharing views and perspectives on CPS implementation in application domains, evolving multi-sided eco-systems as well as business and policy related barriers, enablers and success factors. From the workshops and accompanying activities recommendations for future research and innovation activities were derived and topics and timelines for their implementation proposed. Amongst the technological topics, and related future research priorities ‘integration, interoperability, standards’ ranged highest in all workshops. The topic is connected to digital platforms and reference architectures, which have already become a key priority theme for the EC and their Digitisation Strategy as well as the work on the right standards to help successful implementation of CPSs. Other themes of very high technology/research relevance revealed to be ‘modelling and simulation’, ‘safety and dependability’, ‘security and privacy’, ‘big data and real-time analysis’, ‘ubiquitous autonomy and forecasting’ as well as ‘HMI/human machine awareness’. Next to this, themes emerged including ‘decision making and support’, ‘CPS engineering (requirements, design)’, ‘CPS life-cycle management’, ‘System-of-Systems’, ‘distributed management’, ‘cognitive CPS’, ‘emergence, complexity, adaptability and flexibility’ and work on the foundations of CPS and ‘cross-disciplinary research/CPS Science’