1,465 research outputs found
Development of a toolkit for component-based automation systems
From the earliest days of mass production in the automotive industry there has been a
progressive move towards the use of flexible manufacturing systems that cater for
product variants that meet market demands. In recent years this market has become
more demanding with pressures from legislation, globalisation and increased
customer expectations. This has lead to the current trends of mass customisation in
production.
In order to support this manufacturing systems are not only becoming more flexibleâ€
to cope with the increased product variants, but also more agile‡ such that they may
respond more rapidly to market changes. Modularisation§ is widely used to increase
the agility of automation systems, such that they may be more readily reconfigured¶.
Also with globalisation into India and Asia semi-automatic machines (machines that
interact with human operators) are more frequently used to reduce capital outlay and
increase flexibility. There is an increasing need for tools and methodologies that
support this in order to improve design robustness, reduce design time and gain a
competitive edge in the market.
The research presented in this thesis is built upon the work from
COMPAG/COMPANION (COMponent- based Paradigm for AGile automation, and
COmmon Model for PArtNers in automatION), and as part of the BDA (Business
Driven Automation), SOCRADES (Service Oriented Cross-layer infrastructure for
Distributed smart Embedded deviceS), and IMC-AESOP (ArchitecturE for Service-
Oriented Process – monitoring and control) projects conducted at Loughborough
University UK.
This research details the design and implementation of a toolkit for building and
simulating automation systems comprising components with behaviour described
using Finite State Machines (FSM). The research focus is the development of the
engineering toolkit that can support the automation system lifecycle from initial
design through commissioning to maintenance and reconfiguration as well as the
integration of a virtual human. This is achieved using a novel data structure that
supports component definitions for control, simulation, maintenance and the novel
integration of a virtual human into the automation system operation
FPGA design methodology for industrial control systems—a review
This paper reviews the state of the art of fieldprogrammable gate array (FPGA) design methodologies with a focus on industrial control system applications. This paper starts with an overview of FPGA technology development, followed by a presentation of design methodologies, development tools and relevant CAD environments, including the use of portable hardware description languages and system level programming/design tools. They enable a holistic functional approach with the major advantage of setting up a unique modeling and evaluation environment for complete industrial electronics systems. Three main design rules are then presented. These are algorithm refinement, modularity, and systematic search for the best compromise between the control performance and the architectural constraints. An overview of contributions and limits of FPGAs is also given, followed by a short survey of FPGA-based intelligent controllers for modern industrial systems. Finally, two complete and timely case studies are presented to illustrate the benefits of an FPGA implementation when using the proposed system modeling and design methodology. These consist of the direct torque control for induction motor drives and the control of a diesel-driven synchronous stand-alone generator with the help of fuzzy logic
A component-based virtual engineering approach to PLC code generation for automation systems
In recent years, the automotive industry has been significantly affected by a number of challenges
driven by globalisation, economic fluctuations, environmental awareness and rapid technological developments.
As a consequence, product lifecycles are shortening and customer demands are becoming
more diverse. To survive in such a business environment, manufacturers are striving to find a costeffective
solution for fast and efficient development and reconfiguration of manufacturing systems to
satisfy the needs of changing markets without losses in production.
Production systems within automotive industry are vastly automated and heavily rely on PLC-based
control systems. It has been established that one of the major obstacles in realising reconfigurable
manufacturing systems is the fragmented engineering approach to implement control systems. Control
engineering starts at a very late stage in the overall system engineering process and remains highly
isolated from the mechanical design and build of the system. During this stage, control code is typically
written manually in vendor-specific tools in a combination of IEC 61131-3 languages. Writing
control code is a complex, time consuming and error-prone process. [Continues.
Intuitive Instruction of Industrial Robots : A Knowledge-Based Approach
With more advanced manufacturing technologies, small and medium sized enterprises can compete with low-wage labor by providing customized and high quality products. For small production series, robotic systems can provide a cost-effective solution. However, for robots to be able to perform on par with human workers in manufacturing industries, they must become flexible and autonomous in their task execution and swift and easy to instruct. This will enable small businesses with short production series or highly customized products to use robot coworkers without consulting expert robot programmers. The objective of this thesis is to explore programming solutions that can reduce the programming effort of sensor-controlled robot tasks. The robot motions are expressed using constraints, and multiple of simple constrained motions can be combined into a robot skill. The skill can be stored in a knowledge base together with a semantic description, which enables reuse and reasoning. The main contributions of the thesis are 1) development of ontologies for knowledge about robot devices and skills, 2) a user interface that provides simple programming of dual-arm skills for non-experts and experts, 3) a programming interface for task descriptions in unstructured natural language in a user-specified vocabulary and 4) an implementation where low-level code is generated from the high-level descriptions. The resulting system greatly reduces the number of parameters exposed to the user, is simple to use for non-experts and reduces the programming time for experts by 80%. The representation is described on a semantic level, which means that the same skill can be used on different robot platforms. The research is presented in seven papers, the first describing the knowledge representation and the second the knowledge-based architecture that enables skill sharing between robots. The third paper presents the translation from high-level instructions to low-level code for force-controlled motions. The two following papers evaluate the simplified programming prototype for non-expert and expert users. The last two present how program statements are extracted from unstructured natural language descriptions
Product to process lifecycle management in assembly automation systems
Presently, the automotive industry is facing enormous pressure due to global competition and ever
changing legislative, economic and customer demands. Product and process development in the
automotive manufacturing industry is a challenging task for many reasons. Current product life
cycle management (PLM) systems tend to be product-focussed. Though, information about
processes and resources are there but mostly linked to the product. Process is an important aspect,
especially in assembly automation systems that link products to their manufacturing resources. This
paper presents a process-centric approach to improve PLM systems in large-scale manufacturing
companies, especially in the powertrain sector of the automotive industry. The idea is to integrate
the information related to key engineering chains i.e. products, processes and resources based upon
PLM philosophy and shift the trend of product-focussed lifecycle management to process-focussed
lifecycle management, the outcome of which is the Product, Process and Resource Lifecycle
Management not PLM only
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.
Developing control and integration software for flexible manufacturing systems
The slow growth of computer-integrated manufacturing is attributed to the complexity of designing and implementing their control and integration software. This article expands on a methodology for designing and implementing this software that was introduced in [16]. The goal of this methodology is to build flexible and resuable control and integration software for computer-integrated manufacturing systems. It hinges upon the concepts of software/hardware components, their assemblages, a distributed common language environment, formal models, and generic controllers. Major sources of flexibility are obtained by decoupling process plan models from the model of the factory floor and by using a generic controller. Reusability is achieved by building selfcontained software/hardware components with general, possibly parametrized, interfaces. The interplay between simulated and actual hardware internals of software/hardware components is used as the basis of a testing strategy that performs off-line simulation followed by on-line testing.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/43095/1/10952_2005_Article_BF02265064.pd
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