Modularity and Architecture of PLC-based Software for Automated Production Systems: An analysis in industrial companies

Adaptive and flexible production systems require modular and reusable software especially considering their long term life cycle of up to 50 years. SWMAT4aPS, an approach to measure Software Maturity for automated Production Systems is introduced. The approach identifies weaknesses and strengths of various companie's solutions for modularity of software in the design of automated Production Systems (aPS). At first, a self assessed questionnaire is used to evaluate a large number of companies concerning their software maturity. Secondly, we analyze PLC code, architectural levels, workflows and abilities to configure code automatically out of engineering information in four selected companies. In this paper, the questionnaire results from 16 German world leading companies in machine and plant manufacturing and four case studies validating the results from the detailed analyses are introduced to prove the applicability of the approach and give a survey of the state of the art in industry

Virtual Factory Test of a Cyber-Physical Modular Production System Station

The purpose of this final master’s work is to define guidelines to validate and verify a manufacturing system with elements such as: processes, machines, sensors and actuators through a digital twin and thus validate the discrete control with cyber-physical functionalities. The proposed approach can be used with mechatronic models of existing systems or in concept models to ensure the correct and safe operation of the system. Through the use of digital twins such as a virtual controller and a virtual manufacturing system, the discrete control and motion coordination operation programming logic is validated and verified by applying the GRAFCET, LADDER method and the GEMMA guide for gait modes and stop. In contrast to the traditional start-up, the start-up of the system with cyber-physical functionalities opens an opportunity to the automation area because it incorporates a SCADA system with web functionalities, allowing access to both writing and reading information in multiple platforms and devices connecting physical and virtual systems in the same environment. This document presents the guidelines to systematically implement the validation and verification of a virtual manufacturing system under discrete control with cyberphysical functionalities. For its application, 3 modules were proposed that constitute a virtual manufacturing system considering integration and modularity criteria, representing a real production system. Initially, the methodologies used for the development of the project were shown, seeking to standardize and create guides for virtual start-up thought from the modeling criteria in computer-aided design software, important factors in industrial communications and programming concepts having consider safe modes of operation.El propósito de este trabajo final de maestría es definir pautas para validar y verificar un sistema de manufactura con elementos como: procesos, máquinas, sensores y actuadores por medio de un gemelo digital y de esta manera validar el control discreto con funcionalidades ciberfísicas. El enfoque propuesto puede ser usado con modelos mecatrónicos de sistemas existentes o en modelos de concepto para asegurar la operación correcta y segura del sistema. Mediante el uso de gemelos digitales como el de un controlador virtual y un sistema de manufactura virtual se valida y verifica la lógica de programación de funcionamiento del control discreto y coordinación de movimiento aplicando el método GRAFCET, LADDER y la guía GEMMA de modos de marcha y parada. En contraste con la puesta en marcha tradicional, la puesta en marcha del sistema con funcionalidades ciberfísicas, abre una oportunidad al área de automatización debido a que al incorpora un sistema SCADA con funcionalidades web, permitiendo acceso a la información tanto de escritura como de lectura en múltiples plataformas y dispositivos logrando conectar sistemas físicos y virtuales en un mismo entorno. En este documento se presenta las pautas para implementar sistemáticamente la validación y verificación de un sistema de manufactura virtual bajo control discreto con funcionalidades ciberfísicas. Para su aplicación, se propusieron 3 módulos que constituyan un sistema de manufactura virtual considerando criterios de integración y modularidad representando un sistema de producción real. Inicialmente se mostraron las metodologías utilizadas para el desarrollo del proyecto, buscando estandarizar y crear unas guías para la puesta en marcha virtual pensadas desde el criterio de modelado en un software de diseño asistido por computador, factores importantes en las comunicaciones industriales y conceptos de programación teniendo en cuenta modos seguros de operación.Línea de Investigación: Automatización, Control y MecatrónicaMaestrí