A service-oriented approach to embedded component-based manufacturing automation

This thesis is focused on the application of Component-Based (CB) technology to shop oor devices using a Service Oriented Architecture (SOA) and Web Services (WS) for the purpose of realising future generation agile manufacturing systems. The environment of manufacturing enterprises is now characterised by frequently changing market demands, time-to-market pressure, continuously emerging new technologies and global competition. Under these circumstances, manufacturing systems need to be agile and automation systems need to support this agility. More speci cally, an open, exible automation environment with plug and play connectivity is needed. Technically, this requires the easy connectivity of hardware devices and software components from di erent vendors. Functionally, there is a need of interoperability and integration of control functions on di erent hierarchical levels ranging from eld level to various higher level applications such as process control and operations management services. [Continues.

Design and implementation of a function block-based holonic control architecture for a new generation flexible manufacturing system

In this research work a control architecture which gives response to the requirements of new generation of flexible manufacturing systems in terms of flexibility, reconfigurability, robustness and autonomy is designed and implemented. To do so the main principles of the Holonic Manufacturing paradigm are applied using the IEC61499 function block (FB) technology. Unlike other similar research proposals, in this work FBs are not relegated to low-level control but are used to model manufacturing execution and control high-level control tasks. This is done with the objective of evaluating the viability of using FBs to develop holonic architectures in comparison to more established technologies like multi-agent systems. Moreover, the proposed control architecture also focuses on better integrating and exploiting the products’ information to enhance its flexibility and adaptability. For this STEP-NC (ISO14649) is used to model richer process plans which include manufacturing alternatives and could be easily integrated in the control itself

Towards a new methodology for design, modelling, and verification of reconfigurable distributed control systems based on a new extension to the IEC 61499 standard

In order to meet user requirements and system environment changes, reconfigurable control systems must dynamically adapt their structure and behaviour without disrupting system operation. IEC 61499 standard provides limited support for the design and verification of such systems. In fact, handling different reconfiguration scenarios at runtime is difficult since function blocks in IEC 61499 cannot be changed at run-time. Hence, this thesis promotes an IEC 61499 extension called reconfigurable function block (RFB) that increases design readability and smoothly switches to the most appropriate behaviour when a reconfiguration event occurs. To ensure system feasibility after reconfiguration, in addition to the qualitative verification, quantitative verification based on probabilistic model checking is addressed in a new RFBA approach. The latter aims to transform the designed RFB model automatically into a generalised reconfigurable timed net condition/event system model (GRTNCES) using a newly developed environment called RFBTool. The GR-TNCES fits well with RFB and preserves its semantic. Using the probabilistic model checker PRISM, the generated GR-TNCES model is checked using defined properties specified in computation tree logic. As a result, an evaluation of system performance and an estimation of reconfiguration risks are obtained. The RFBA methodology is applied on a distributed power system case study.Dynamische Anforderungen und Umgebungen erfordern rekonfigurierbare Anlagen und Steuerungssysteme. Rekonfiguration ermöglicht es einem System, seine Struktur und sein Verhalten an interne oder externe Änderungen anzupassen. Die Norm IEC 61499 wurde entwickelt, um (verteilte) Steuerungssysteme auf Basis von Funktionsbausteinen zu entwickeln. Sie bietet jedoch wenig Unterstützung für Entwurf und Verifikation. Die Tatsache, dass eine Rekonfiguration das System-Ausführungsmodell verändert, erschwert die Entwicklung in IEC 61499 zusätzlich. Daher schlägt diese Dissertation rekonfigurierbare Funktionsbausteine (RFBs) als Erweiterung der Norm vor. Ein RFB verarbeitet über einen Master-Slave-Automaten Rekonfigurationsereignisse und löst das entsprechende Verhalten aus. Diese Hierarchie trennt das Rekonfigurationsmodell vom Steuerungsmodell und vereinfacht so den Entwurf. Die Funktionalität des Entwurfs muss verifiziert werden, damit die Ausführbarkeit des Systems nach einer Rekonfiguration gewährleistet ist. Hierzu wird das entworfene RFB-Modell automatisch in ein generalised reconfigurable timed net condition/event system übersetzt. Dieses wird mit dem Model-Checker PRISM auf qualitative und quantitative Eigenschaften überprüft. Somit wird eine Bewertung der Systemperformanz und eine Einschätzung der Rekonfigurationsrisiken erreicht. Die RFB-Methodik wurde in einem Softwarewerkzeug umgesetzt und in einer Fallstudie auf ein dezentrales Stromnetz angewendet

Design of automatic control system based on unified timed hybrid Petri net

A practical problem in automation systems modeling is the choice between a fully hybrid approach and the fluidization of some parts conserving the general discrete event approach. This paper explores the approach based on specific hybrid parts into a discrete event system using a unified Petri nets environment called GHENeSys (General Hierarchical Enhanced Net System), which follows the ISO/IEC 15909 standard and includes extensions such as hierarchy and time concepts. Then, a design method based on GHENeSys Timed Hybrid Petri Net (GTHPN) technique is proposed to model these hybrid parts. GHENeSys subnets are associated with macro-places and help to control combinatorial explosion and has extended arcs to guarantee the GTHPN applicability to practical cases. All resulting models of the approach proposed could also benefit from an easier conversion to PLC programs in IEC 61131 representation. A case study is presented for producing constructive blocks showing the advantages of the current proposition.Un problema práctico en sistemas automatizados es la selección entre el enfoque totalmente híbrido o la fluidización de algunas partes conservando el enfoque general de eventos discretos. Este articulo trata el enfoque basado en partes hibridas en un modelo discreto usando el ambiente unificado de Redes de Petri llamado GHENeSys (Sistema de Red Extendida Jerárquica General), compatible con la norma ISO/IEC 15909 incluyendo los conceptos de jerarquía y tiempo. Por tanto, se propone un método de diseño y una técnica GTHPN (Redes de Petri Temporizadas Hibridas GHENeSys) para modelar estas partes híbridas. Las subredes en macro-lugares controlan la explosión de estados y controlar transiciones mediante arcos extendidos de GHENeSys garantiza la efectividad de GTHPN para casos prácticos. Además, todo modelo resultante permite una fácil conversión a programas de PLCs en lenguajes IEC61131. Se presenta un caso de estudio para producción de bloques de construcción demostrando estas ventajas mencionadas

Web service control of component-based agile manufacturing systems

Current global business competition has resulted in significant challenges for manufacturing and production sectors focused on shorter product lifecyc1es, more diverse and customized products as well as cost pressures from competitors and customers. To remain competitive, manufacturers, particularly in automotive industry, require the next generation of manufacturing paradigms supporting flexible and reconfigurable production systems that allow quick system changeovers for various types of products. In addition, closer integration of shop floor and business systems is required as indicated by the research efforts in investigating "Agile and Collaborative Manufacturing Systems" in supporting the production unit throughout the manufacturing lifecycles. The integration of a business enterprise with its shop-floor and lifecycle supply partners is currently only achieved through complex proprietary solutions due to differences in technology, particularly between automation and business systems. The situation is further complicated by the diverse types of automation control devices employed. Recently, the emerging technology of Service Oriented Architecture's (SOA's) and Web Services (WS) has been demonstrated and proved successful in linking business applications. The adoption of this Web Services approach at the automation level, that would enable a seamless integration of business enterprise and a shop-floor system, is an active research topic within the automotive domain. If successful, reconfigurable automation systems formed by a network of collaborative autonomous and open control platform in distributed, loosely coupled manufacturing environment can be realized through a unifying platform of WS interfaces for devices communication. The adoption of SOA- Web Services on embedded automation devices can be achieved employing Device Profile for Web Services (DPWS) protocols which encapsulate device control functionality as provided services (e.g. device I/O operation, device state notification, device discovery) and business application interfaces into physical control components of machining automation. This novel approach supports the possibility of integrating pervasive enterprise applications through unifying Web Services interfaces and neutral Simple Object Access Protocol (SOAP) message communication between control systems and business applications over standard Ethernet-Local Area Networks (LAN's). In addition, the re-configurability of the automation system is enhanced via the utilisation of Web Services throughout an automated control, build, installation, test, maintenance and reuse system lifecycle via device self-discovery provided by the DPWS protocol...cont'd

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

Engineering framework for service-oriented automation systems

Tese de doutoramento. Engenharia Informática. Universidade do Porto. Faculdade de Engenharia. 201

Software Systems Engineering for Cyber Physical Production Systems

This project solves the problem of easy adaption and usage of CPPS by small scale industries, With this project it has been tried to develop a methodology of requirement engineering for CPPS system and finally the whole system. We have developed the approach right from requirement engineering to mapping into IEC61499 function blocks and then to deployment to a physical devices. This work can be a good foundation and support for scientific communities or industialist to easily implement requirement engineering of a small scale systems for CPPS and thus build a 21st century production system with this and reap its enormous benefits.Cyber physical production systems are the future of production systems not only in europe but in the entire world. It brings with itself huge benefits and popularly attributes to Industry 4.0 also. These are automated systems where physical systems are monitored and controlled by computer based algorithms in real time. Traditional systems have certain disadvantages and are limited in terms of hours of operation as it is governed by manpowers and the type of products that can be produced without making much changes in the production configuration and the speed of production of products. In europe, a lot of research is going on, particularly in germany and in the United states too for upgrading major physical systems and manufacturing systems. Some examples of such systems are smart factory, smart grid, autonomous automobile systems, automatic pilot avionics, robotics systems etc. The main goal of this thesis is to define a set of methodologies for easing the process of implementation of the CPPS(cyber physical production systems) system on small and medium industries so that the adoption rate for such industries can be high. There is no methodology yet particularly for CPPS systems for small and medium industries, although we have methodologies in place for large industries. In order to do so, first study was done for challenges in developing a requirement engineering process in section 3 and how it is different from a typical software system. An approach has been developed based on existing information available on large systems and CPPS and some software engineering frameworks like MODAF and TOGAF. A proposal for the process and some diagrams and tools has been made in section 4. To validate the proposed approach we have taken a synthetic test case of a pizza production system and implemented all the approaches to transform it into a cyber physical production system right from requirement and UML diagrams to the final function block approach. With this set of approaches,there is now a basis for software development methodology for small and medium industries particularly. With these approaches the adoption rate can be really high for such industries bringing out traditional industries more to the 21st century forefront

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.

Agent-based manufacturing — review and expert evaluation

The advent of smart manufacturing and the exposure to a new generation of technological enablers have revolutionized the way manufacturing process is carried out. Cyber-Physical Production Systems (CPPS) are introduced as main actors of this manufacturing shift. They are characterized for having high levels of communication, integration and computational capabilities that led them to a certain level of autonomy. Despite the high expectations and vision of CPPS, it still remains an exploratory topic. Multi-Agent Systems (MAS) have been widely used by software engineers to solve traditional computing problems, e.g., banking transactions. Because of their high levels of distribution and autonomous capabilities, MAS have been considered by the research community as a good solution to design and implement CPPS. This work first introduces a collection of requirements and characteristics of smart manufacturing. A comprehensive review of various research applications is presented to understand the current state of the art and the application of agent technology in manufacturing. Considering the smart manufacturing requirements and current research application, a SWOT analysis was formulated which identifies pros and cons of the implementation of agents in industry. The SWOT analysis was further validated by an industrial expert evaluation and the main findings and discussion of the results are presented