A Distributed-Ledger, Edge-Computing Architecture for Automation and Computer Integration in Semiconductor Manufacturing

Contemporary 300mm semiconductor manufacturing systems have highly automated and digitalized cyber-physical integration. They suffer from the profound problems of integrating large, centralized legacy systems with small islands of automation. With the recent advances in disruptive technologies, semiconductor manufacturing has faced dramatic pressures to reengineer its automation and computer integrated systems. This paper proposes a Distributed- Ledger, Edge-Computing Architecture (DLECA) for automation and computer integration in semiconductor manufacturing. Based on distributed ledger and edge computing technologies, DLECA establishes a decentralized software framework where manufacturing data are stored in distributed ledgers and processed locally by executing smart contracts at the edge nodes. We adopt an important topic of automation and computer integration for semiconductor research & development (R&D) operations as the study vehicle to illustrate the operational structure and functionality, applications, and feasibility of the proposed DLECA software framewor

Design of a Control System for a Reconfigurable Engine Assembly Line

Today’s automotive manufacturing environment is dynamic. It is characterized by short life cycles of products especially in powertrain, due in part to changing Government regulations for fuel economy. In the USA, the National Highway Traffic and Safety Administration (NHTSA), Corporate Average Fuel Economy (CAFE) mandates an average of 29 miles per gallon (mpg), gradually increasing to 35.5 mpg by 2016 and 54.5 mpg towards 2025. Life cycles of engines and transmissions have consequently shortened, driving automakers to develop and manufacture more efficient powertrains. Not long ago, plants produced engines for decades, with minor modifications warranting slight manufacturing line rework. Conversely, today’s changing trends require machines and complete engine line overhauls rendering initial setups obsolete. Automakers compete to satisfy government regulations for best mileage and also lower manufacturing cost, thus the adoption of Reconfigurable Manufacturing Systems (RMS). Production lines follow modularity in designs, for hardware and software, to adapt to new business conditions, economically and time-wise. Information Technology (IT) and Controls are growing closer with the line of demarcation disappearing in manufacturing. Controls are benefiting from opportunities in IT, hardware and software. The advent of agent-based technology which are autonomous, cooperative and extendible in different production activities, helped to develop controls for RMS in academia. Component-based software suitable for RMS modularity and plug-and-play hardware/software components has gained decades of popularity in the software industry. This thesis implements distributed controls imbedding component-based technology and IEC 61311-3 function block standard for automotive engine assembly, which will contribute to these developments. The control architecture provides reconfigurability which is lacking in current manufacturing systems. The research imbeds: 1- Reconfigurability - Fitting RMS-designed hardware towards new manufacturing, 2- Reusability - Building software library for reuse across assembly lines, and 3- Plug-and-Play - Embedding easy to assemble software components (function blocks)

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.

Lightweight robust behavior industrial agent methodology

Dissertação para obtenção do Grau de Mestre em Engenharia Electrotécnica e de ComputadoresAssembly systems today face significant pressure to provide highly adaptable and quickly deployable solutions in order to deal with unpredictable changes according to market trends. However, control of assembly processes are dominated by the use of Programmable Logical Controllers (PLC) which do not provide the necessary mechanisms to easily deal with these challenges. The concept of agent-based control has been introduced as a solution to deal these challenges and support new production paradigms based on the plug and produce concept. However, this solution has not yet been proven to be a real alternative to the traditional PLC approach in terms of performance. This work is investigating the use an approach that is able to benefit from the relative advantages of both PLC and agents solutions. A new hybrid architecture is presented which combines the functionalities of a PLC with those of industrial agents. The focus is on assessing the performance of this approach and help change the minds of an industry averse to changes

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

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.

Physical Agents and RFID for the implementation of the Shop Floor Control on a Distribution Centre.

[ES] En la última década, la aplicación de la tecnología de sistemas multiagente para el control en planta ha generado gran expectación por parte de profesionales e investigadores. El uso de esta tecnología, por la propia definición de los agentes como: sistemas reactivos (capaces de responder ante cambios en el entorno), proactivos (generando iniciativas dirigidas a alcanzar sus objetivos), autónomos y con capacidades sociales (la toma de decisiones está consensuada), ha propiciado la aparición de gran cantidad de iniciativas. Lamentablemente, la mayoría de estas iniciativas se reducen únicamente a definiciones de agentes, declaración de intenciones o simulaciones, o bien constituyen propuestas demasiado ambiciosas, lo que ha impedido que la industria adopte este tipo de soluciones. Este artículo presenta una aproximación para la implementación de los agentes encargados del control en planta, conocidos como agentes físicos u holones, sobre una plataforma experimental que representa las instalaciones de un centro de distribución automatizado. Se ha tomado como punto de partida el concepto de holón, pero se ha adaptado de manera que la toma de decisiones tenga lugar en el controlador industrial. El trabajo se ha centrado en alcanzar una toma de decisiones en planta inteligente. Se definen dos tipos de agentes y se ha modelado, mediante redes de Petri, la forma en la que interaccionan estos agentes en la toma de decisiones que surgen en el funcionamiento de una planta inteligente. Finalmente los modelos se han implementado sobre autómatas programables.[EN] The application of the multi-agent systems technology for shop-floor control has generated great expectations among professionals and researchers in the last decade. The use of this technology conveys, by the definition of the agents, reactive systems (able to respond to changes), proactive systems (their behavior is oriented towards the achievement of predefined objectives), autonomy, and social skills (consensual decision making), causing the emergence of many initiatives. Unfortunately, most references on this field are mainly concerned with: the definition of agents, statements of intent, simulations or rather ambitious proposals; which prevents industry from adopting this technology.This paper presents an approach to implement the agents in charge of the shop floor control, known as physical agents or holons, on a test bench that represent the installations of an automated distributed center. The concept of holon has been adapted to keep the decision making in the industrial controller. The work is focused on reach an intelligent decision making at the shop floor. For what, two kind of agents have been defined, and the decision makings at shop floor have been modelled by means of Petri Nets. Finally, models have been implemented over programmable logic controllers.Este trabajo ha sido desarrollado con el respaldo del Ministerio Español de Economía y Competitividad mediante la ayuda de referencia DPI2012-35227 al proyecto de título: “Sipail: Seguimiento Integral en Producción, Automatización Industrial y Logística”.De Las Morenas, J.; García, A.; Martínez, F.; García Ansola, P. (2015). Implementación del Control en Planta de un Centro de Distribución Automatizado mediante Agentes Físicos y RFID. Revista Iberoamericana de Automática e Informática industrial. 12(1):25-35. https://doi.org/10.1016/j.riai.2014.11.002OJS2535121Brennan, R., Gruver, W., Hall, K., 2011. Forward-Special Issue on Industrial Applications of Holonic Manufacturing Systems. 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