Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

New Shop Floor Control Approaches for Virtual Enterprises

The virtual enterprise paradigm seems a fit response to face market instability and the volatile nature of business opportunities increasing enterprise’s interest in similar forms of networked organisations. The dynamic environment of a virtual enterprise requires that partners in the consortium own reconfigurable shop floors. This paper presents new approaches to shop floor control that meet the requirements of the new industrial paradigms and argues on work re-organization at shop floor level.virtual enterprise; networked organisations

Industrial Fieldbus Improvements in Power Distribution and Conducted Noise Immunity With No Extra Costs

Industrial distributed control continues the move toward networks at all levels. At lower levels, control networks provide flexibility, reliability, and low cost, although perhaps the simplest but most important advantage is the reduced volume of wiring. Powered fieldbuses offer particular notable benefits in system wiring simplification. Nevertheless, very few papers are dealing with the potentials and limitations in power distribution through the bus cable. Only a few of the existent fieldbus standards consider this possibility but often simply as an option without enough technical specifications. In fact, nobody talks about it, but power distribution through the bus and conducted noise disturbances are strongly related. This paper points out and analyzes these limitations and proposes a new low-cost fieldbus physical layer that enlarges power distribution capability of the bus and improves system robustness. We show an industrial application on water desalination plants and the very good results obtained owing to the fieldbus. Finally, we present electromagnetic compatibility test results that verify improvements against electrical fast transients on the sensor/actuator connection side as disturbances usually encountered in harsh-environment industrial applications

Operator interfaces for the lifecycle support of component based automation systems

Current manufacturing automation systems (specifically the powertrain sector) have been facing challenges with constant pressures of globalisation, environmental concerns and ICT (Information and Communication Technology) innovations. These challenges instigate new demands for shorter product lifecycles and require customised products to be manufactured as efficiently as possible. Manufacturing systems must therefore be agile to remain competitive by supporting frequent reconfigurations involving distributed engineering activities. [Continues.

The Cyber Physical Implementation of Cloud Manufactuirng Monitoring Systems

AbstractThe rise of the industrial internet has been envisaged as a key catalyst for creating the intelligent manufacturing plant of the future through enabling open data distribution for cloud manufacturing. The context supporting these systems has been defined by Service Oriented Architectures (SOA) that facilitate data resource and computational functions as services available on a network. SOA has been at the forefront EU research over the past decade and several industrially implemented SOA technologies exist on the manufacturing floor. However it is still unclear whether SOA can meet the multi-layered requirements present within state-of-the-art manufacturing Cyber Physical Systems (CPS). The focus of this research is to identify the capability of SOA to be implemented at different execution layers present in a manufacturing CPS. The state-of-the-art for manufacturing CPS is represented by the ISA-95 standard and is correlated with different temporal analysis scales, and manufacturing computational requirements. Manufacturing computational requirements are identified through a review of open and closed loop machine control orientations, and continuous and discrete control methods. Finally the Acquire Recognise Cluster (ARC) SOA for reconfigurable manufacturing process monitoring systems is reviewed, to provide a topological view of data flow within a field level manufacturing SOA

Engineering methods and tools for cyber–physical automation systems

Much has been published about potential benefits of the adoption of cyber–physical systems (CPSs) in manufacturing industry. However, less has been said about how such automation systems might be effectively configured and supported through their lifecycles and how application modeling, visualization, and reuse of such systems might be best achieved. It is vitally important to be able to incorporate support for engineering best practice while at the same time exploiting the potential that CPS has to offer in an automation systems setting. This paper considers the industrial context for the engineering of CPS. It reviews engineering approaches that have been proposed or adopted to date including Industry 4.0 and provides examples of engineering methods and tools that are currently available. The paper then focuses on the CPS engineering toolset being developed by the Automation Systems Group (ASG) in the Warwick Manufacturing Group (WMG), University of Warwick, Coventry, U.K. and explains via an industrial case study how such a component-based engineering toolset can support an integrated approach to the virtual and physical engineering of automation systems through their lifecycle via a method that enables multiple vendors' equipment to be effectively integrated and provides support for the specification, validation, and use of such systems across the supply chain, e.g., between end users and system integrators

Cyber-Virtual Systems: Simulation, Validation & Visualization

We describe our ongoing work and view on simulation, validation and visualization of cyber-physical systems in industrial automation during development, operation and maintenance. System models may represent an existing physical part - for example an existing robot installation - and a software simulated part - for example a possible future extension. We call such systems cyber-virtual systems. In this paper, we present the existing VITELab infrastructure for visualization tasks in industrial automation. The new methodology for simulation and validation motivated in this paper integrates this infrastructure. We are targeting scenarios, where industrial sites which may be in remote locations are modeled and visualized from different sites anywhere in the world. Complementing the visualization work, here, we are also concentrating on software modeling challenges related to cyber-virtual systems and simulation, testing, validation and verification techniques for them. Software models of industrial sites require behavioural models of the components of the industrial sites such as models for tools, robots, workpieces and other machinery as well as communication and sensor facilities. Furthermore, collaboration between sites is an important goal of our work.Comment: Preprint, 9th International Conference on Evaluation of Novel Approaches to Software Engineering (ENASE 2014

A categorical framework of manufacturing for industry 4.0 and beyond

AbstractWith rapid advancements in industry, technology and applications, many concepts have emerged in manufacturing. It is generally known that the far-sighted term ‘Industry 4.0’ was published to highlight a new industrial revolution. Many manufacturing organizations and companies are researching this topic. However, the achievement criteria of Industry 4.0 are as yet uncertain. In addition, the technology roadmap of accomplishing Industry 4.0 is still not clear in industry nor in academia to date. This paper focuses on the fundamental conception of Industry 4.0 and the state of current manufacturing systems. It also identifies the research gaps between current manufacturing systems and Industry 4.0 requirements. The major contribution is an implementation structure of Industry 4.0, consisting of a multi-layered framework is described, and is shown how it can assist people in understanding and achieving the requirements of Industry 4.0