Design and Implementation of an expert System for Monitoring and Management of Web-Based Industrial Applications Master Thesis

Human is an intelligent creature – intelligent in design and behaviour. From the human first second on the earth, he is trying to collect the knowledge and use it for surviving and extending his own kind. Human knowledge collection is all based on his observa-tions and discovering for his own environment, the information with time turns to be the human experience which is the main sort of his intelligence of dealing with different situations. Expert system is one branch of artificial intelligence science which the human in-spired from his own being. Human always tries to inherit his own experiences to the next generations. But with the vast wide spreading of the information in the present century, a new need imposed itself to emulate the human experience and behaviour in a similar way; from this point expert computer systems have been invented. Expert system is mainly transforming the human experiences into software forms. To act in a similar manner the human behaves. The expert system is always collecting a huge amount of information from its domain, and transform them to knowledge, using those rules the human assigned based on his own experiences. In industry we try to apply the same concept to have intelligent automated system, but for this purpose; all the information should be in an easy form of industrial language and follow a reliable industrial protocol to communicate in an efficient way. As the internet is the main source of the data on our planet currently, it was so con-venient to structure all the industrial data in same language the internet use and follow similar communication protocols. From industrial point of view a web based monitoring systems – should be the base of information for the mentioned expert system. During this master thesis we achieve this goal, by dividing the problem into two main sub problems. The first part is to implement a web based monitoring system on PLC controlled produc-tion line made by FESTO and used for teaching purpose in TUT - Tampere University of Technology – FASTory lab facilities. The second part is to design and implement a convenient industrial expert system to process this web based monitored information for managing from the business point of vie

A Real-Time Service-Oriented Architecture for Industrial Automation

Industrial automation platforms are experiencing a paradigm shift. New technologies are making their way in the area, including embedded real-time systems, standard local area networks like Ethernet, Wi-Fi and ZigBee, IP-based communication protocols, standard service oriented architectures (SOAs) and Web services. An automation system will be composed of flexible autonomous components with plug & play functionality, self configuration and diagnostics, and autonomic local control that communicate through standard networking technologies. However, the introduction of these new technologies raises important problems that need to be properly solved, one of these being the need to support real-time and quality-of-service (QoS) for real-time applications. This paper describes a SOA enhanced with real-time capabilities for industrial automation. The proposed architecture allows for negotiation of the QoS requested by clients from Web services, and provides temporal encapsulation of individual activities. This way, it is possible to perform an a priori analysis of the temporal behavior of each service, and to avoid unwanted interference among them. After describing the architecture, experimental results gathered on a real implementation of the framework (which leverages a soft real-time scheduler for the Linux kernel) are presented, showing the effectiveness of the proposed solution. The experiments were performed on simple case studies designed in the context of industrial automation applications

Integration issues in the development of a modelling and simulation tool for low volume high-complexity electronics manufacture

In order to design and implement the information systems and modules that could comprise an “industrial strong” knowledge-based tool, links to shop floor systems containing real-time production data and PCA customer information (e.g. bill of materials (BOM), CAD drawings) are required. Details of the issues of implementing the tool in an industrial organisation and the integration of various data sources (e.g. “in-house” developed systems, enterprise resource planning systems, ad-hoc developed databases, machine data and CAD data) are presented in this paper. The application of the CLOVES system in an industrial setup highlights the difficulties in integrating information from design as CAD data and shows how these setbacks could be overcome if the electronics industry were to adopt a common CAD assembly information exchange platform. Hence, this paper concludes that existing automation tool manufacturers should focus exclusively on developing generic connections by adopting industry standards that can facilitate the deployment of “plug and play” tools. This standardisation could in turn help software developers, to provide the electronics industry with more integrated systems that communicate better among loosely coupled information systems and avoid depending on extensive time consuming manual data input

Towards a software framework for reconfigurable and adaptive fixturing systems

There is an ongoing trend towards advanced fixturing systems that can be automatically reconfigured for different workpieces and dynamically adapt the clamping forces during the manufacturing process. However, the increased utilisation of computer technology and sensor feedback currently requires a significant amount of programming effort during the development phase and deployment of such fixtures which impairs their successful industrial realisation. This research addresses the issue by developing the core concepts of a novel software framework that facilitates the deployment and operation of reconfigurable and adaptive fixturing systems. This includes a new data model for the representation of the fixturing system, using object-oriented modelling techniques. Secondly, a generic methodology for the automatic reconfiguration of fixturing systems has been developed that can be applied to a plethora of different fixture layouts. Thirdly, a flexible communication infrastructure is proposed which supports the platform-independent communication between the various parts of the fixturing system through the adoption of a publish/subscribe approach. The integration of these core knowledge contributions into a software framework significantly reduces the programming effort by providing a ready-to-use infrastructure that can be configured according a given fixture layout. In order to manage the complexity of the research, a structured research methodology has been followed. Based on an extensive literature review, a number of knowledge gaps have been identified which were the basis for the definition of clear research objectives. A use case analysis has been conducted to identify the requirements of the software framework and several potential middleware technologies have been assessed for the communication infrastructure. This was followed by the development of the three core knowledge contributions. Finally, the research results have been demonstrated and initially verified with a prototype of a reconfigurable fixturing system, indicating that the utilisation of the software framework can eliminate the need for programming, thereby drastically reducing deployment effort and lead time

Towards a software framework for reconfigurable and adaptive fixturing systems

There is an ongoing trend towards advanced fixturing systems that can be automatically reconfigured for different workpieces and dynamically adapt the clamping forces during the manufacturing process. However, the increased utilisation of computer technology and sensor feedback currently requires a significant amount of programming effort during the development phase and deployment of such fixtures which impairs their successful industrial realisation. This research addresses the issue by developing the core concepts of a novel software framework that facilitates the deployment and operation of reconfigurable and adaptive fixturing systems. This includes a new data model for the representation of the fixturing system, using object-oriented modelling techniques. Secondly, a generic methodology for the automatic reconfiguration of fixturing systems has been developed that can be applied to a plethora of different fixture layouts. Thirdly, a flexible communication infrastructure is proposed which supports the platform-independent communication between the various parts of the fixturing system through the adoption of a publish/subscribe approach. The integration of these core knowledge contributions into a software framework significantly reduces the programming effort by providing a ready-to-use infrastructure that can be configured according a given fixture layout. In order to manage the complexity of the research, a structured research methodology has been followed. Based on an extensive literature review, a number of knowledge gaps have been identified which were the basis for the definition of clear research objectives. A use case analysis has been conducted to identify the requirements of the software framework and several potential middleware technologies have been assessed for the communication infrastructure. This was followed by the development of the three core knowledge contributions. Finally, the research results have been demonstrated and initially verified with a prototype of a reconfigurable fixturing system, indicating that the utilisation of the software framework can eliminate the need for programming, thereby drastically reducing deployment effort and lead time

A communication module for capturing events in order to monitor a service-based automated production line

The efficiency, reliability and on time maintenance of a manufacturing process largely relies on a highly efficient and rapidly responsive monitoring system. The increasing demand of uninterrupted continuation of a production process emphasizes the need of anefficient real time monitoring mechanism of the process. The rapid advancements of modern technology especially in the communication field have largely affected every field of daily life as well as the industrial sector. The rise of wireless communication technology has made it possible to develop wireless sensors for industrial monitoring applications and revolutionize the monitoring techniques to a greater extent. The work researches a web based monitoring approach for real time monitoring of service-oriented production assembly with 3D visualization. The implementation deals with the design and implementation of a communication framework for receiving, processing and publishing events information of a service oriented assembly line. The processed information is then linked and simulated with a 3D replica of the actual process over the web in real time. The work demonstrates the usefulness of versatile features of 3D visualization in industrial monitoring applications. The online accessibility of the monitoring application enables all concerned individuals to access and monitor the manufacturing process in real time from any remote location. The developed web application can also be simulated for a given set of historical data. Currently, the research work focuses on capturing and simulating only two types of shop floor messages (Pallet activity notification message and Robot activity equipment change state message), but can be enhanced to include more features of the robotic assembly line in future

Complex low volume electronics simulation tool to improve yield and reliability

Assembly of Printed Circuit Boards (PCB) in low volumes and a high-mix requires a level of manual intervention during product manufacture, which leads to poor first time yield and increased production costs. Failures at the component-level and failures that stem from non-component causes (i.e. system-level), such as defects in design and manufacturing, can account for this poor yield. These factors have not been incorporated in prediction models due to the fact that systemfailure causes are not driven by well-characterised deterministic processes. A simulation and analysis support tool being developed that is based on a suite of interacting modular components with well defined functionalities and interfaces is presented in this paper. The CLOVES (Complex Low Volume Electronics Simulation) tool enables the characterisation and dynamic simulation of complete design; manufacturing and business processes (throughout the entire product life cycle) in terms of their propensity to create defects that could cause product failure. Details of this system and how it is being developed to fulfill changing business needs is presented in this paper. Using historical data and knowledge of previous printed circuit assemblies (PCA) design specifications and manufacturing experiences, defect and yield results can be effectively stored and re-applied for future problem solving. For example, past PCA design specifications can be used at design stage to amend designs or define process options to optimise the product yield and service reliability

Combining business process and failure modelling to increase yield in electronics manufacturing

The prediction and capturing of defects in low-volume assembly of electronics is a technical challenge that is a prerequisite for design for manufacturing (DfM) and business process improvement (BPI) to increase first-time yields and reduce production costs. Failures at the component-level (component defects) and system-level (such as defects in design and manufacturing) have not been incorporated in combined prediction models. BPI efforts should have predictive capability while supporting flexible production and changes in business models. This research was aimed at the integration of enterprise modelling (EM) and failure models (FM) to support business decision making by predicting system-level defects. An enhanced business modelling approach which provides a set of accessible failure models at a given business process level is presented in this article. This model-driven approach allows the evaluation of product and process performance and hence feedback to design and manufacturing activities hence improving first-time yield and product quality. A case in low-volume, high-complexity electronics assembly industry shows how the approach leverages standard modelling techniques and facilitates the understanding of the causes of poor manufacturing performance using a set of surface mount technology (SMT) process failure models. A prototype application tool was developed and tested in a collaborator site to evaluate the integration of business process models with the execution entities, such as software tools, business database, and simulation engines. The proposed concept was tested for the defect data collection and prediction in the described case study