REMOTE MONITORING AND CONTROL OF A RECONFIGURABLE SYSTEM USING A WEB INTERFACE

ThesisThe assembly system at the Research Group in Evolvable Manufacturing System (RGEMS) is designed to assemble products part by part and also ensuring good quality products. This system uses different kinds of industrial devices that are integrated in a way that the devices are dependent on each other in order to work properly on a production cycle. The disadvantage of systems of this nature is that if one of the devices malfunctions and is not attended to, the production line will get affected, which will cost time and money. In order to ensure that malfunctioning of devices is acknowledged in time, the system devices must be monitored while busy in progress; this is normally done by a system operator who uses a computer and checks if there is any change in system data using a Supervisory Control and Data Acquisition (SCADA) system. This is, however, inconvenient in that the system operator can only monitor and control the system when connected to the system’s network. Today we live in a wireless world, where anything can be accessible from anywhere in the world; internet and web technologies made all this possible. It was therefore proposed to design a system that can monitor and control the assembly system from a remote location. This system uses OLE Process Control (OPC) technology and web technology in order to read and write data to the system from the OPC server through the internet. This data is presented on a web user interface where it is viewed as analogue or digital data. The user only needs the internet browser installed to his/her computer or smart phone and also to be authorized by the system administrator in order to be able to monitor and control the system

Process control and configuration of a reconfigurable production system using a multi-agent software system

Thesis (M. Tech. (Information Technology)) -- Central University of technology, Free State, 2011Traditional designs for component-handling platforms are rigidly linked to the product being produced. Control and monitoring methods for these platforms consist of various proprietary hardware controllers containing the control logic for the production process. Should the configuration of the component handling platform change, the controllers need to be taken offline and reprogrammed to take the changes into account. The current thinking in component-handling system design is the notion of re-configurability. Reconfigurability means that with minimum or no downtime the system can be adapted to produce another product type or overcome a device failure. The re-configurable component handling platform is built-up from groups of independent devices. These groups or cells are each responsible for some aspect of the overall production process. By moving or swopping different versions of these cells within the component-handling platform, re-configurability is achieved. Such a dynamic system requires a flexible communications platform and high-level software control architecture to accommodate the reconfigurable nature of the system. This work represents the design and testing of the core of a re-configurable production control software platform. Multiple software components work together to control and monitor a re-configurable component handling platform. The design and implementation of a production database, production ontology, communications architecture and the core multi-agent control application linking all these components together is presented

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

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches