Reconfigurable conveyor transfer system using IEC-61499 function blocks

Mestrado de dupla diplomação com o Centro Federal de Educação Tecnológica de Minas Gerais – CEFET-MGIn the 4th Industrial Revolution era, automation processes operate in a more modular, flexible, and reconfigurable manner, leveraging decentralized decision-making and distributed control. As the backbone of this revolution lies the Cyber-physical Production System (CPPS) concept, which emphasizes the strong interlink and interdependence of the digital/cyber and physical components. It requires the use of a technology capable of incorporating intelligence through the entities in a decentralized manner. IEC-61499 Function Blocks technology stands out as a suitable approach to implementing distributed automation control systems. This work presents the development of a dynamic and on-the-fly reconfiguration conveyor transfer system based on the IEC-61499 standard, that automatically adapts its operation to face changes in the number and position of the conveyor modules. For this purpose, the developed control system considers a Python-based Function Block (FB) network using the DINASORE framework, capable of effectively communicating between system components and identifying changes in real time. The experimental tests showed promising results regarding the system’s ability to adapt to condition changes automatically and on the fly, as well as its scalability and robustness.Na era da 4ª Revolução Industrial, os processos de automação operam de maneira mais modular, flexível e reconfigurável, aproveitando a tomada de decisão descentralizada e o controle distribuído. O conceito de Sistemas de Produção Cíber Físicos (do inglês Cyber-physical Production System - CPPS) surge como o principal componente dessa revolução, enfatizando a forte interligação e interdependência dos componentes digitais/cibernéticos e físicos, exigindo o uso de uma tecnologia capaz de incorporar inteligência por meio das entidades de forma descentralizada. A tecnologia de Function Blocks baseados na norma IEC-61499 destaca-se como uma abordagem adequada para implementar sistemas de controle de automação distribuídos. Este trabalho apresenta o desenvolvimento de um sistema dinâmico de transferência de esteira transportadora e de reconfiguração baseado na norma IEC-61499, adaptando automaticamente sua operação para enfrentar mudanças no número e na posição dos módulos da esteira. Para isso, o sistema de controle desenvolvido considera uma rede de FB baseada em Python usando o DINASORE, capaz de se comunicar efetivamente entre os componentes do sistema e identificar alterações em tempo real. Os testes experimentais mostraram resultados promissores com relação à capacidade do sistema de se adaptar às mudanças automaticamente e em tempo real, bem como sua escalabilidade e robustez

Towards a new methodology for design, modelling, and verification of reconfigurable distributed control systems based on a new extension to the IEC 61499 standard

In order to meet user requirements and system environment changes, reconfigurable control systems must dynamically adapt their structure and behaviour without disrupting system operation. IEC 61499 standard provides limited support for the design and verification of such systems. In fact, handling different reconfiguration scenarios at runtime is difficult since function blocks in IEC 61499 cannot be changed at run-time. Hence, this thesis promotes an IEC 61499 extension called reconfigurable function block (RFB) that increases design readability and smoothly switches to the most appropriate behaviour when a reconfiguration event occurs. To ensure system feasibility after reconfiguration, in addition to the qualitative verification, quantitative verification based on probabilistic model checking is addressed in a new RFBA approach. The latter aims to transform the designed RFB model automatically into a generalised reconfigurable timed net condition/event system model (GRTNCES) using a newly developed environment called RFBTool. The GR-TNCES fits well with RFB and preserves its semantic. Using the probabilistic model checker PRISM, the generated GR-TNCES model is checked using defined properties specified in computation tree logic. As a result, an evaluation of system performance and an estimation of reconfiguration risks are obtained. The RFBA methodology is applied on a distributed power system case study.Dynamische Anforderungen und Umgebungen erfordern rekonfigurierbare Anlagen und Steuerungssysteme. Rekonfiguration ermöglicht es einem System, seine Struktur und sein Verhalten an interne oder externe Änderungen anzupassen. Die Norm IEC 61499 wurde entwickelt, um (verteilte) Steuerungssysteme auf Basis von Funktionsbausteinen zu entwickeln. Sie bietet jedoch wenig Unterstützung für Entwurf und Verifikation. Die Tatsache, dass eine Rekonfiguration das System-Ausführungsmodell verändert, erschwert die Entwicklung in IEC 61499 zusätzlich. Daher schlägt diese Dissertation rekonfigurierbare Funktionsbausteine (RFBs) als Erweiterung der Norm vor. Ein RFB verarbeitet über einen Master-Slave-Automaten Rekonfigurationsereignisse und löst das entsprechende Verhalten aus. Diese Hierarchie trennt das Rekonfigurationsmodell vom Steuerungsmodell und vereinfacht so den Entwurf. Die Funktionalität des Entwurfs muss verifiziert werden, damit die Ausführbarkeit des Systems nach einer Rekonfiguration gewährleistet ist. Hierzu wird das entworfene RFB-Modell automatisch in ein generalised reconfigurable timed net condition/event system übersetzt. Dieses wird mit dem Model-Checker PRISM auf qualitative und quantitative Eigenschaften überprüft. Somit wird eine Bewertung der Systemperformanz und eine Einschätzung der Rekonfigurationsrisiken erreicht. Die RFB-Methodik wurde in einem Softwarewerkzeug umgesetzt und in einer Fallstudie auf ein dezentrales Stromnetz angewendet

Low-cost Industrial controller based on the Raspberry Pi platform

Mestrado de dupla diplomação com o Centro Federal de Educação Tecnológica Celso Suckow da Fonseca - CEFET/RJThe low-cost automation field exhibits the need of innovation both in terms of hardware and software. There is a lack of devices that allow the development of control logic that is free from restrictions of domain-specific communication platforms and at the same time able to provide the capabilities aligned to the Industry 4.0 requirements. The objective of this work is to develop an inexpensive, small Industrial Controller that supports the execution of programs in different industrial programming languages. So, it is intended to develop, manufacture and control a low-cost but powerful Industrial Controller based on the use of the single-board computer Raspberry Pi. The study described in this document was carried out on the creation of a hardware platform that is capable of integrating with software frameworks compatible with standards updated and widely used in the industrial automation field. IEC 61131-3 is employed displaying the ease of use and implementation alongside multiple well established programming languages for automation through the OpenPLC platform while IEC 61449 is employed through the 4DIAC framework that has a clear and objective environment capable of providing the appropriate tools for implementation of a distributed control. It is employed the single-board computer Raspberry Pi, a robust device with adequate processing power and communication capability for the elaboration of a platform in the low-cost automation scope. The elaboration of the Industrial Shields, responsible for providing the controller I/O interface took into consideration maintenance concerns of controller integrity through the application of galvanic isolation in the automaton input and output sections. The proposed platform was successfully tested in an automation system prototype comprising Fischertechnik’s Punching Machine being possible to develop the control logic using IEC 61131-3 and IEC 61499.O campo de automação de baixo custo demonstra a necessidade de inovação em termos de hardware e software. Há uma falta de dispositivos que permitem o desenvolvimento de lógica de controle livre de restrições de plataformas de comunicação específicas de domínio e, ao mesmo tempo, capazes de fornecer os recursos alinhados aos requisitos da Indústria 4.0. O objetivo deste trabalho é desenvolver um pequeno Controlador Industrial de baixo custo que suporte a execução de programas em diferentes linguagens de programação industrial. Assim, pretende-se desenvolver, fabricar e controlar um Controlador Industrial de baixo custo, mas poderoso, baseado no uso do computador de placa única Raspberry Pi. O estudo descrito neste documento foi realizado na criação de uma plataforma de hardware que é capaz de se integrar com frameworks de software compatíveis com padrões atualizados e amplamente utilizados na área de automação industrial. A IEC 61131-3 é empregada exibindo a facilidade de uso e implementação juntamente com várias linguagens de programação bem estabelecidas para automação através da plataforma OpenPLC enquanto a IEC 61449 é empregada através da estrutura 4DIAC que possui um ambiente claro e objetivo capaz de fornecer as ferramentas apropriadas para implementação de um controle distribuído. É empregado o computador de placa única Raspberry Pi, um dispositivo robusto com capacidade de processamento e capacidade de comunicação adequados para a elaboração de uma plataforma no escopo de automação de baixo custo. A elaboração dos industrial shields, responsáveis por fornecer a interface de I/O do controlador levou em consideração as preocupações de manutenção da integridade do controlador através da aplicação de isolação galvânica nas seções de entrada e saída do autômato. A plataforma proposta foi testada com sucesso em um protótipo de sistema de automação compreendendo a Punching Machine da Fischertechnik sendo possível desenvolver a lógica de controle usando IEC 61131-3 e IEC 61499

Standardization in cyber-physical systems: the ARUM case

Cyber-physical systems concept supports the realization of the Industrie 4.0 vision towards the computerization of traditional industries, aiming to achieve intelligent and reconfigurable factories. Standardization assumes a critical role in the industrial adoption of cyber-physical systems, namely in the integration of legacy systems as well as the smooth migration from existing running systems to the new ones. This paper analyses some existing standards in related fields and presents identified limitations and efforts for a wider acceptance of such systems by industry. A special attention is devoted to the efforts to develop a standard-compliant service-oriented multi-agent system solution within the ARUM project.info:eu-repo/semantics/publishedVersio

A Novel Method for Adaptive Control of Manufacturing Equipment in Cloud Environments

The ability to adaptively control manufacturing equipment, both in local and distributed environments, is becoming increasingly more important for many manufacturing companies. One important reason for this is that manufacturing companies are facing increasing levels of changes, variations and uncertainty, caused by both internal and external factors, which can negatively impact their performance. Frequently changing consumer requirements and market demands usually lead to variations in manufacturing quantities, product design and shorter product life-cycles. Variations in manufacturing capability and functionality, such as equipment breakdowns, missing/worn/broken tools and delays, also contribute to a high level of uncertainty. The result is unpredictable manufacturing system performance, with an increased number of unforeseen events occurring in these systems. Events which are difficult for traditional planning and control systems to satisfactorily manage. For manufacturing scenarios such as these, the use of real-time manufacturing information and intelligence is necessary to enable manufacturing activities to be performed according to actual manufacturing conditions and requirements, and not according to a pre-determined process plan. Therefore, there is a need for an event-driven control approach to facilitate adaptive decision-making and dynamic control capabilities. Another reason driving the move for adaptive control of manufacturing equipment is the trend of increasing globalization, which forces manufacturing industry to focus on more cost-effective manufacturing systems and collaboration within global supply chains and manufacturing networks. Cloud Manufacturing is evolving as a new manufacturing paradigm to match this trend, enabling the mutually advantageous sharing of resources, knowledge and information between distributed companies and manufacturing units. One of the crucial objectives for Cloud Manufacturing is the coordinated planning, control and execution of discrete manufacturing operations in collaborative and networked environments. Therefore, there is also a need that such an event-driven control approach supports the control of distributed manufacturing equipment. The aim of this research study is to define and verify a novel and comprehensive method for adaptive control of manufacturing equipment in cloud environments. The presented research follows the Design Science Research methodology. From a review of research literature, problems regarding adaptive manufacturing equipment control have been identified. A control approach, building on a structure of event-driven Manufacturing Feature Function Blocks, supported by an Information Framework, has been formulated. The Function Block structure is constructed to generate real-time control instructions, triggered by events from the manufacturing environment. The Information Framework uses the concept of Ontologies and The Semantic Web to enable description and matching of manufacturing resource capabilities and manufacturing task requests in distributed environments, e.g. within Cloud Manufacturing. The suggested control approach has been designed and instantiated, implemented as prototype systems for both local and distributed manufacturing scenarios, in both real and virtual applications. In these systems, event-driven Assembly Feature Function Blocks for adaptive control of robotic assembly tasks have been used to demonstrate the applicability of the control approach. The utility and performance of these prototype systems have been tested, verified and evaluated for different assembly scenarios. The proposed control approach has many promising characteristics for use within both local and distributed environments, such as cloud environments. The biggest advantage compared to traditional control is that the required control is created at run-time according to actual manufacturing conditions. The biggest obstacle for being applicable to its full extent is manufacturing equipment controlled by proprietary control systems, with native control languages. To take the full advantage of the IEC Function Block control approach, controllers which can interface, interpret and execute these Function Blocks directly, are necessary

Multi-Agent Modelling of Industrial Cyber-Physical Systems for IEC 61499 Based Distributed Intelligent Automation

Traditional industrial automation systems developed under IEC 61131-3 in centralized architectures are statically programmed with determined procedures to perform predefined tasks in structured environments. Major challenges are that these systems designed under traditional engineering techniques and running on legacy automation platforms are unable to automatically discover alternative solutions, flexibly coordinate reconfigurable modules, and actively deploy corresponding functions, to quickly respond to frequent changes and intelligently adapt to evolving requirements in dynamic environments. The core objective of this research is to explore the design of multi-layer automation architectures to enable real-time adaptation at the device level and run-time intelligence throughout the whole system under a well-integrated modelling framework. Central to this goal is the research on the integration of multi-agent modelling and IEC 61499 function block modelling to form a new automation infrastructure for industrial cyber-physical systems. Multi-agent modelling uses autonomous and cooperative agents to achieve run-time intelligence in system design and module reconfiguration. IEC 61499 function block modelling applies object-oriented and event-driven function blocks to realize real-time adaption of automation logic and control algorithms. In this thesis, the design focuses on a two-layer self-manageable architecture modelling: a) the high-level cyber module designed as multi-agent computing model consisting of Monitoring Agent, Analysis Agent, Self-Learning Agent, Planning Agent, Execution Agent, and Knowledge Agent; and b) the low-level physical module designed as agent-embedded IEC 61499 function block model with Self-Manageable Service Execution Agent, Self-Configuration Agent, Self-Healing Agent, Self-Optimization Agent, and Self-Protection Agent. The design results in a new computing module for high-level multi-agent based automation architectures and a new design pattern for low-level function block modelled control solutions. The architecture modelling framework is demonstrated through various tests on the multi-agent simulation model developed in the agent modelling environment NetLogo and the experimental testbed designed on the Jetson Nano and Raspberry Pi platforms. The performance evaluation of regular execution time and adaptation time in two typical conditions for systems designed under three different architectures are also analyzed. The results demonstrate the ability of the proposed architecture to respond to major challenges in Industry 4.0

Anpassen verteilter eingebetteter Anwendungen im laufenden Betrieb

The availability of third-party apps is among the key success factors for software ecosystems: The users benefit from more features and innovation speed, while third-party solution vendors can leverage the platform to create successful offerings. However, this requires a certain decoupling of engineering activities of the different parties not achieved for distributed control systems, yet. While late and dynamic integration of third-party components would be required, resulting control systems must provide high reliability regarding real-time requirements, which leads to integration complexity. Closing this gap would particularly contribute to the vision of software-defined manufacturing, where an ecosystem of modern IT-based control system components could lead to faster innovations due to their higher abstraction and availability of various frameworks. Therefore, this thesis addresses the research question: How we can use modern IT technologies and enable independent evolution and easy third-party integration of software components in distributed control systems, where deterministic end-to-end reactivity is required, and especially, how can we apply distributed changes to such systems consistently and reactively during operation? This thesis describes the challenges and related approaches in detail and points out that existing approaches do not fully address our research question. To tackle this gap, a formal specification of a runtime platform concept is presented in conjunction with a model-based engineering approach. The engineering approach decouples the engineering steps of component definition, integration, and deployment. The runtime platform supports this approach by isolating the components, while still offering predictable end-to-end real-time behavior. Independent evolution of software components is supported through a concept for synchronous reconfiguration during full operation, i.e., dynamic orchestration of components. Time-critical state transfer is supported, too, and can lead to bounded quality degradation, at most. The reconfiguration planning is supported by analysis concepts, including simulation of a formally specified system and reconfiguration, and analyzing potential quality degradation with the evolving dataflow graph (EDFG) method. A platform-specific realization of the concepts, the real-time container architecture, is described as a reference implementation. The model and the prototype are evaluated regarding their feasibility and applicability of the concepts by two case studies. The first case study is a minimalistic distributed control system used in different setups with different component variants and reconfiguration plans to compare the model and the prototype and to gather runtime statistics. The second case study is a smart factory showcase system with more challenging application components and interface technologies. The conclusion is that the concepts are feasible and applicable, even though the concepts and the prototype still need to be worked on in future -- for example, to reach shorter cycle times.Eine große Auswahl von Drittanbieter-Lösungen ist einer der Schlüsselfaktoren für Software Ecosystems: Nutzer profitieren vom breiten Angebot und schnellen Innovationen, während Drittanbieter über die Plattform erfolgreiche Lösungen anbieten können. Das jedoch setzt eine gewisse Entkopplung von Entwicklungsschritten der Beteiligten voraus, welche für verteilte Steuerungssysteme noch nicht erreicht wurde. Während Drittanbieter-Komponenten möglichst spät -- sogar Laufzeit -- integriert werden müssten, müssen Steuerungssysteme jedoch eine hohe Zuverlässigkeit gegenüber Echtzeitanforderungen aufweisen, was zu Integrationskomplexität führt. Dies zu lösen würde insbesondere zur Vision von Software-definierter Produktion beitragen, da ein Ecosystem für moderne IT-basierte Steuerungskomponenten wegen deren höherem Abstraktionsgrad und der Vielzahl verfügbarer Frameworks zu schnellerer Innovation führen würde. Daher behandelt diese Dissertation folgende Forschungsfrage: Wie können wir moderne IT-Technologien verwenden und unabhängige Entwicklung und einfache Integration von Software-Komponenten in verteilten Steuerungssystemen ermöglichen, wo Ende-zu-Ende-Echtzeitverhalten gefordert ist, und wie können wir insbesondere verteilte Änderungen an solchen Systemen konsistent und im Vollbetrieb vornehmen? Diese Dissertation beschreibt Herausforderungen und verwandte Ansätze im Detail und zeigt auf, dass existierende Ansätze diese Frage nicht vollständig behandeln. Um diese Lücke zu schließen, beschreiben wir eine formale Spezifikation einer Laufzeit-Plattform und einen zugehörigen Modell-basierten Engineering-Ansatz. Dieser Ansatz entkoppelt die Design-Schritte der Entwicklung, Integration und des Deployments von Komponenten. Die Laufzeit-Plattform unterstützt den Ansatz durch Isolation von Komponenten und zugleich Zeit-deterministischem Ende-zu-Ende-Verhalten. Unabhängige Entwicklung und Integration werden durch Konzepte für synchrone Rekonfiguration im Vollbetrieb unterstützt, also durch dynamische Orchestrierung. Dies beinhaltet auch Zeit-kritische Zustands-Transfers mit höchstens begrenzter Qualitätsminderung, wenn überhaupt. Rekonfigurationsplanung wird durch Analysekonzepte unterstützt, einschließlich der Simulation formal spezifizierter Systeme und Rekonfigurationen und der Analyse der etwaigen Qualitätsminderung mit dem Evolving Dataflow Graph (EDFG). Die Real-Time Container Architecture wird als Referenzimplementierung und Evaluationsplattform beschrieben. Zwei Fallstudien untersuchen Machbarkeit und Nützlichkeit der Konzepte. Die erste verwendet verschiedene Varianten und Rekonfigurationen eines minimalistischen verteilten Steuerungssystems, um Modell und Prototyp zu vergleichen sowie Laufzeitstatistiken zu erheben. Die zweite Fallstudie ist ein Smart-Factory-Demonstrator, welcher herausforderndere Applikationskomponenten und Schnittstellentechnologien verwendet. Die Konzepte sind den Studien nach machbar und nützlich, auch wenn sowohl die Konzepte als auch der Prototyp noch weitere Arbeit benötigen -- zum Beispiel, um kürzere Zyklen zu erreichen

An approach to task coordination for hyperflexible robotic workcells

2014 - 2015The manufacturing industry is very diverse and covers a wide range of specific processes ranging from extracting minerals to assembly of very complex products such as planes or computers, with all intermediate processing steps in a long chain of industrial suppliers and customers. It is well know that the introduction of robots in manufacturing industries has many advantages. Basically, in relation to human labor, robots work to a constant level of quality. For example, waste, scrap and rework are minimized. Furthermore they can work in areas that are hazardous or unpleasant to humans. Robots are advantageous where strength is required, and in many applications they are also faster than humans. Also, in relation to special-purpose dedicated equipment, robots are more easily reprogrammed to cope with new products or changes in the design of existing ones. In the last 30-40 years, large enterprises in high-volume markets have managed to remain competitive and maintain qualified jobs by increasing their productivity with the incremental adoption and use of advanced ICT and robotics technologies. In the 70s, robots have been introduced for the automation of a wide spectrum of tasks such as: assembly of cars, white goods, electronic devices, machining of metal and plastic parts, and handling of workpieces and objects of all kinds. Robotics has thus soon become a synonym for competitive manufacturing and a key contributing technology for strengthening the economic base of Europe . So far, the automotive and electronics industries and their supply chains are the main users of robot systems and are accounting for more than 60% of the total annual robot sales. Robotic technologies have thus mainly been driven by the needs of these high-volume market industries. The degree of automation in the automotive industries is expected to increase in the future as robots will push the limits towards flexibility regarding faster change-over-times of different product types (through rapid programming generation schemes), capabilities to deal with tolerances (through an extensive use of sensors) and costs (by reducing customized work-cell installations and reuse of manufacturing equipment). There are numerous new fields of applications in which robot technology is not widespread today due to its lack of flexibility and high costs involved when dealing with varying lot sizes and variable product geometries. In such cases, hyper-flexible robotic work cells can help in providing flexibility to the system and making it adaptable to the different dynamic production requirements. Hyper-flexible robotic work cells, in fact, can be composed of sets of industrial robotic manipulators that cooperate to achieve the production step that characterize the work cell; they can be programmed and re-programmed to achieve a wide class of operations and they may result versatile to perform different kind of tasks Related key technology challenges for pursuing successful long-term industrial robot automation are introduced at three levels: basic technologies, robot components and systems integration. On a systems integration level, the main challenges lie in the development of methods and tools for instructing and synchronising the operation of a group of cooperative robots at the shop-floor. Furthermore, the development of the concept of hyper flexible manufacturing systems implies soon the availability of: consistent middleware for automation modules to seamlessly connect robots, peripheral devices and industrial IT systems without reprogramming everything (”plug-and-play”) . In this thesis both innovative and traditional industrial robot applications will be analyzed from the point of view of task coordination. In the modeling environment, contribution of this dissertation consists in presenting a new methodology to obtain a model oriented to the control the sequencing of the activities of a robotic hyperflexible cell. First a formal model using the Colored Modified Hybrid Petri Nets (CMHPN) is presented. An algorithm is provided to obtain an automatic synthesis of the CMHPN of a robotic cell with detail attention to aircraft industry. It is important to notice that the CMHPN is used to model the cell behaviour at a high level of abstraction. It models the activities of each cell component and its coordination by a supervisory system. As more, an object oriented approach and supervisory control are proposed to implement industrial automation control systems (based on Programmable Logic Controllers) to meet the new challenges of this field capability to implement applications involving widely distributed devices and high reuse of software components. Hence a method is proposed to implement both controllers and supervisors designed by Petri Nets on Programmable Logic Controllers (PLCs) using Object Oriented Programming (OOP). Finally preliminary results about a novel cyber-physical approach to the design of automated warehouse systems is presented. [edited by author]XIV n.s