A framework for smart production-logistics systems based on CPS and industrial IoT

Industrial Internet of Things (IIoT) has received increasing attention from both academia and industry. However, several challenges including excessively long waiting time and a serious waste of energy still exist in the IIoT-based integration between production and logistics in job shops. To address these challenges, a framework depicting the mechanism and methodology of smart production-logistics systems is proposed to implement intelligent modeling of key manufacturing resources and investigate self-organizing configuration mechanisms. A data-driven model based on analytical target cascading is developed to implement the self-organizing configuration. A case study based on a Chinese engine manufacturer is presented to validate the feasibility and evaluate the performance of the proposed framework and the developed method. The results show that the manufacturing time and the energy consumption are reduced and the computing time is reasonable. This paper potentially enables manufacturers to deploy IIoT-based applications and improve the efficiency of production-logistics systems

Improvement of powertrain mechatronic systems for lean automotive manufacturing

In recent years, the increasing severity of emission standards forced car manufacturers to integrate vehicle powertrains with additional mechatronic elements, consisting in sensors, executors and controlling elements interacting with each other. However, the introduction of the best available ecological devices goes hand in hand with the legislation and/or limitations in different regional markets. Thus, the designers adapt the mechatronic system to the target emission standards of the produced powertrain. The software embedded into the Engine Control Unit (ECU) is highly customized for the specific configurations: variability in mechatronic systems leads to the development of several software versions, lowering the efficiency of the design phase. Therefore the employment of a standard for the communication among sensors, actuators and the ECU would allow the development of a unique software for different configurations; this would be beneficial from a manufacturing point of view, enabling the simplification of the design process. Obviously, the new software must still guarantee the proper level of feedbacks to the ECU to ensure the compliance with different emission standards and the proper engine behavior. The general software is adapted to the powertrain: according to the specific target emission standard, some control elements may not be necessary, and a part of the software may be easily removed. In this paper, starting from a real case-study, a more general methodology is proposed for configurations characterized by different powertrain sets and manufacturing line constraints. The proposed technique allows to maintain the accuracy of the control system and improve process efficiency at the same time, ensuring lean production and lowering manufacturing costs. A set of mathematical techniques to improve software efficacy is also presented: the resulting benefits are enhanced by software standardization, because the design effort may be shared by the largest possible number of applications

Standardized Classification and Interfaces of Complex Behaviour Models in Virtual Commissioning

AbstractToday's increasing use of Virtual Commissioning during the development process of automated manufacturing plants paired with the increasing request towards better control quality leads to the need of improved virtual plants with more effortless set ups. The common techniques of simulating the plant within Virtual Commissioning do no longer fulfil these needs, new approaches have to be developed. This paper examines ways to standardize Functional Mock-Up Unit based behaviour models of mechatronic components of such automated manufacturing plants. It is argued how such components can be classified to reach a distinction between different types to be able to develop standardized interfaces for every type. Therefore a standardized framework of how these interfaces can look like is proposed. Based on this framework as well as the classification of the components two examples, a pneumatic valve cylinder combination and an industrial robot are exemplarily implemented. Besides the standard interfaces to the control program and the visualisation of the simulation a special effort to implement energetically considerations were made. Therefore the presented work shows a way of how to standardize the interfaces of behaviour models of different classes of mechatronic components while increasing the quality of these behaviour models for more complex and accurate behaviour simulation of production plants for Virtual Commissioning as well as related applications

Last Generation Mechatronics: a Two-level Platform-based Reconfigurable Technology Approach

As is well known mechatronic systems currently being designed and developed are often difficult multidisciplinary undertakings. Based on the intrinsic coupling of different implementation technologies, efficient design of mechatronic systems is of primordial importance for development of next generation industrial products. This paper is focused to current and future technological trends aimed to improve the design and implementation processes of mechatronic systems in an increasingly harsh industrial environment. Special attention is dedicated to introduction of the two-level platform-based reconfigurable technology approach. This strategy efficiently combines major advantages of both the hardware and software platform-based development trends in modern mecatronic systems. In order to support the unfolded theoretical arguments a last generation and versatile mechatronic system development is presented and discussed in the paper. The mentioned trends can be used as rough orientation for future mechatronic systems research and implementation activities

Automated data-driven creation of the Digital Twin of a brownfield plant

The success of the reconfiguration of existing manufacturing systems, so called brownfield systems, heavily relies on the knowledge about the system. Reconfiguration can be planned, supported and simplified with the Digital Twin of the system providing this knowledge. However, digital models as the basis of a Digital Twin are usually missing for these plants. This article presents a data-driven approach to gain knowledge about a brownfield system to create the digital models of a Digital Twin and their relations. Finally, a proof of concept shows that process data and position data as data sources deliver the relations between the models of the Digital Twin.Comment: 7 Pages, 5 figures. Accepted at IEEE ETFA 202

Feasibility study of electromechanical cylinder drivetrain for offshore mechatronic systems

Currently, there is an increasing focus on the environmental impact and energy consumption of the oil and gas industry. In offshore drilling equipment, electric motors tend to replace traditionally used hydraulic motors, especially in rotational motion control applications. However, force densities available from linear hydraulic actuators are still typically higher than those of electric actuators. Therefore, usually the remaining source of hydraulic power is thereby the hydraulic cylinder. This paper presents a feasibility study on the implementation of an electromechanical cylinder drivetrain on an offshore vertical pipe handling machine. The scope of this paper is to investigate the feasibility of a commercial off-the-shelf drivetrain. With a focus on the motion performance, numerical modeling and simulation are used when sizing and selecting the components of the considered electromechanical cylinder drivetrain. The simulation results are analyzed and discussed together with a literature study regarding advantages and disadvantages of the proposed solution considering the design criteria of offshore drilling equipment. It is concluded that the selected drivetrain can only satisfy the static motion requirements since the required transmitted power is higher than the recommended permissible power of the transmission screw. Consequently, based on the recommendation of the manufacturer, avoidance of overheating cannot be guaranteed for the drivetrain combinations considered for the case study presented in this paper. Hence, to avoid overheating, the average speed of the motion cycle must be decreased. Alternatively, external cooling or temperature monitoring and control system that prevents overheating could be implemented

Product Design

Product design is a comprehensive process related to the creation of new products, and the ability to design and develop efficient products are key to success in today’s dynamic global market. Written by experts in the field, this book provides a comprehensive overview of the product design process and its applications in various fields, particularly engineering. Over seven chapters, the authors explore such topics as development of new product design methodologies, implementation of effective methods for integrated products, development of more visualized environments for task-based conceptual design methods, and development of engineering design tools based on 3D photogrammetry, among others