Web service control of component-based agile manufacturing systems

Current global business competition has resulted in significant challenges for manufacturing and production sectors focused on shorter product lifecyc1es, more diverse and customized products as well as cost pressures from competitors and customers. To remain competitive, manufacturers, particularly in automotive industry, require the next generation of manufacturing paradigms supporting flexible and reconfigurable production systems that allow quick system changeovers for various types of products. In addition, closer integration of shop floor and business systems is required as indicated by the research efforts in investigating "Agile and Collaborative Manufacturing Systems" in supporting the production unit throughout the manufacturing lifecycles. The integration of a business enterprise with its shop-floor and lifecycle supply partners is currently only achieved through complex proprietary solutions due to differences in technology, particularly between automation and business systems. The situation is further complicated by the diverse types of automation control devices employed. Recently, the emerging technology of Service Oriented Architecture's (SOA's) and Web Services (WS) has been demonstrated and proved successful in linking business applications. The adoption of this Web Services approach at the automation level, that would enable a seamless integration of business enterprise and a shop-floor system, is an active research topic within the automotive domain. If successful, reconfigurable automation systems formed by a network of collaborative autonomous and open control platform in distributed, loosely coupled manufacturing environment can be realized through a unifying platform of WS interfaces for devices communication. The adoption of SOA- Web Services on embedded automation devices can be achieved employing Device Profile for Web Services (DPWS) protocols which encapsulate device control functionality as provided services (e.g. device I/O operation, device state notification, device discovery) and business application interfaces into physical control components of machining automation. This novel approach supports the possibility of integrating pervasive enterprise applications through unifying Web Services interfaces and neutral Simple Object Access Protocol (SOAP) message communication between control systems and business applications over standard Ethernet-Local Area Networks (LAN's). In addition, the re-configurability of the automation system is enhanced via the utilisation of Web Services throughout an automated control, build, installation, test, maintenance and reuse system lifecycle via device self-discovery provided by the DPWS protocol...cont'd

A service-oriented approach to embedded component-based manufacturing automation

This thesis is focused on the application of Component-Based (CB) technology to shop oor devices using a Service Oriented Architecture (SOA) and Web Services (WS) for the purpose of realising future generation agile manufacturing systems. The environment of manufacturing enterprises is now characterised by frequently changing market demands, time-to-market pressure, continuously emerging new technologies and global competition. Under these circumstances, manufacturing systems need to be agile and automation systems need to support this agility. More speci cally, an open, exible automation environment with plug and play connectivity is needed. Technically, this requires the easy connectivity of hardware devices and software components from di erent vendors. Functionally, there is a need of interoperability and integration of control functions on di erent hierarchical levels ranging from eld level to various higher level applications such as process control and operations management services. [Continues.

A next generation manufacturing control system for a lean production environment

This thesis focuses on addressing the need for a new approach to the design and implementation of manufacturing control systems for the automotive industry and in particular for high volume engine manufacture. Whilst the operational domain in the automotive industry has moved to lean production techniques, the design of presentday manufacturing control systems is still based on systems intended for use in a mass production environment. The design and implementation of current manufacturing control systems is therefore inappropriate when viewed from a business context. The author proposes that it is possible to create a more appropriate manufacturing control systems based on an optimised use of advanced manufacturing technology within the complete business context. Literature is reviewed to provide a detailed understanding of the relationship between modem operating practices and the application of contemporary control systems. The primary tasks of manufacturing control systems, within the context of a structured systems approach to manufacturing technology, production management and industrial economics are identified. A study of modem manufacturing control system technology is carried out, highlighting the fundamental principles that influence application engineering in this area. The thesis develops a conceptual design framework that aids the identification of attributes required of a next generation manufacturing control system (NGCS), in order to enhance the business performance of lean automotive manufacturing. The architecture for a next generation control system is specified and a Proof of concept system implemented. Potential advances over contemporary practice are identified with the aid of a practical implementation at a major automotive manufacturer

Industry 4.0 for SMEs

This open access book explores the concept of Industry 4.0, which presents a considerable challenge for the production and service sectors. While digitization initiatives are usually integrated into the central corporate strategy of larger companies, smaller firms often have problems putting Industry 4.0 paradigms into practice. Small and medium-sized enterprises (SMEs) possess neither the human nor financial resources to systematically investigate the potential and risks of introducing Industry 4.0. Addressing this obstacle, the international team of authors focuses on the development of smart manufacturing concepts, logistics solutions and managerial models specifically for SMEs. Aiming to provide methodological frameworks and pilot solutions for SMEs during their digital transformation, this innovative and timely book will be of great use to scholars researching technology management, digitization and small business, as well as practitioners within manufacturing companies

Industry 4.0 for SMEs

This open access book explores the concept of Industry 4.0, which presents a considerable challenge for the production and service sectors. While digitization initiatives are usually integrated into the central corporate strategy of larger companies, smaller firms often have problems putting Industry 4.0 paradigms into practice. Small and medium-sized enterprises (SMEs) possess neither the human nor financial resources to systematically investigate the potential and risks of introducing Industry 4.0. Addressing this obstacle, the international team of authors focuses on the development of smart manufacturing concepts, logistics solutions and managerial models specifically for SMEs. Aiming to provide methodological frameworks and pilot solutions for SMEs during their digital transformation, this innovative and timely book will be of great use to scholars researching technology management, digitization and small business, as well as practitioners within manufacturing companies

Novel Validation Techniques for Autonomous Vehicles

L'abstract è presente nell'allegato / the abstract is in the attachmen

Intelligent maintenance management in a reconfigurable manufacturing environment using multi-agent systems

Thesis (M. Tech.) -- Central University of Technology, Free State, 2010Traditional corrective maintenance is both costly and ineffective. In some situations it is more cost effective to replace a device than to maintain it; however it is far more likely that the cost of the device far outweighs the cost of performing routine maintenance. These device related costs coupled with the profit loss due to reduced production levels, makes this reactive maintenance approach unacceptably inefficient in many situations. Blind predictive maintenance without considering the actual physical state of the hardware is an improvement, but is still far from ideal. Simply maintaining devices on a schedule without taking into account the operational hours and workload can be a costly mistake. The inefficiencies associated with these approaches have contributed to the development of proactive maintenance strategies. These approaches take the device health state into account. For this reason, proactive maintenance strategies are inherently more efficient compared to the aforementioned traditional approaches. Predicting the health degradation of devices allows for easier anticipation of the required maintenance resources and costs. Maintenance can also be scheduled to accommodate production needs. This work represents the design and simulation of an intelligent maintenance management system that incorporates device health prognosis with maintenance schedule generation. The simulation scenario provided prognostic data to be used to schedule devices for maintenance. A production rule engine was provided with a feasible starting schedule. This schedule was then improved and the process was determined by adhering to a set of criteria. Benchmarks were conducted to show the benefit of optimising the starting schedule and the results were presented as proof. Improving on existing maintenance approaches will result in several benefits for an organisation. Eliminating the need to address unexpected failures or perform maintenance prematurely will ensure that the relevant resources are available when they are required. This will in turn reduce the expenditure related to wasted maintenance resources without compromising the health of devices or systems in the organisation

Novel Validation Techniques for Autonomous Vehicles

The automotive industry is facing challenges in producing electrical, connected, and autonomous vehicles. Even if these challenges are, from a technical point of view, independent from each other, the market and regulatory bodies require them to be developed and integrated simultaneously. The development of autonomous vehicles implies the development of highly dependable systems. This is a multidisciplinary activity involving knowledge from robotics, computer science, electrical and mechanical engineering, psychology, social studies, and ethics. Nowadays, many Advanced Driver Assistance Systems (ADAS), like Emergency Braking System, Lane Keep Assistant, and Park Assist, are available. Newer luxury cars can drive by themselves on highways or park automatically, but the end goal is to develop completely autonomous driving vehicles, able to go by themselves, without needing human interventions in any situation. The more vehicles become autonomous, the greater the difficulty in keeping them reliable. It enhances the challenges in terms of development processes since their misbehaviors can lead to catastrophic consequences and, differently from the past, there is no more a human driver to mitigate the effects of erroneous behaviors. Primary threats to dependability come from three sources: misuse from the drivers, design systematic errors, and random hardware failures. These safety threats are addressed under various aspects, considering the particular type of item to be designed. In particular, for the sake of this work, we analyze those related to Functional Safety (FuSa), viewed as the ability of a system to react on time and in the proper way to the external environment. From the technological point of view, these behaviors are implemented by electrical and electronic items. Various standards to achieve FuSa have been released over the years. The first, released in 1998, was the IEC 61508. Its last version is the one released in 2010. This standard defines mainly: • a Functional Safety Management System (FSMS); • methods to determine a Safety Integrated Level (SIL); • methods to determine the probability of failures. To adapt the IEC61508 to the automotive industry’s peculiarity, a newer standard, the ISO26262, was released in 2011 then updated in 2018. This standard provides guidelines about FSMS, called in this case Safety Lifecycle, describing how to develop software and hardware components suitable for functional safety. It also provides a different way to compute the SIL, called in this case Automotive SIL (ASIL), allowing us to consider the average driver’s abilities to control the vehicle in case of failures. Moreover, it describes a way to determine the probability of random hardware failures through Failure Mode, Effects, and Diagnostic Analysis (FMEDA). This dissertation contains contributions to three topics: • random hardware failures mitigation; • improvementoftheISO26262HazardAnalysisandRiskAssessment(HARA); • real-time verification of the embedded software. As the main contribution of this dissertation, I address the safety threats due to random hardware failures (RHFs). For this purpose, I propose a novel simulation-based approach to aid the Failure Mode, Effects, and Diagnostic Analysis (FMEDA) required by the ISO26262 standard. Thanks to a SPICE-level model of the item, and the adoption of fault injection techniques, it is possible to simulate its behaviors obtaining useful information to classify the various failure modes. The proposed approach evolved from a mere simulation of the item, allowing only an item-level failure mode classification up to a vehicle-level analysis. The propagation of the failure modes’ effects on the whole vehicle enables us to assess the impacts on the vehicle’s drivability, improving the quality of the classifications. It can be advantageous where it is difficult to predict how the item-level misbehaviors propagate to the vehicle level, as in the case of a virtual differential gear or the mobility system of a robot. It has been chosen since it can be considered similar to the novel light vehicles, such as electric scooters, that are becoming more and more popular. Moreover, my research group has complete access to its design since it is realized by our university’s DIANA students’ team. When a SPICE-level simulation is too long to be performed, or it is not possible to develop a complete model of the item due to intellectual property protection rules, it is possible to aid this process through behavioral models of the item. A simulation of this kind has been performed on a mobile robotic system. Behavioral models of the electronic components were used, alongside mechanical simulations, to assess the software failure mitigation capabilities. Another contribution has been obtained by modifying the main one. The idea was to make it possible to aid also the Hazard Analysis and Risk Assessment (HARA). This assessment is performed during the concept phase, so before starting to design the item implementation. Its goal is to determine the hazards involved in the item functionality and their associated levels of risk. The end goal of this phase is a list of safety goals. For each one of these safety goals, an ASIL has to be determined. Since HARA relies only on designers expertise and knowledge, it lacks in objectivity and repeatability. Thanks to the simulation results, it is possible to predict the effects of the failures on the vehicle’s drivability, allowing us to improve the severity and controllability assessment, thus improving the objectivity. Moreover, since simulation conditions can be stored, it is possible, at any time, to recheck the results and to add new scenarios, improving the repeatability. The third group of contributions is about the real-time verification of embedded software. Through Hardware-In-the-Loop (HIL), a software integration verification has been performed to test a fundamental automotive component, mixed-criticality applications, and multi-agent robots. The first of these contributions is about real-time tests on Body Control Modules (BCM). These modules manage various electronic accessories in the vehicle’s body, like power windows and mirrors, air conditioning, immobilizer, central locking. The main characteristics of BCMs are the communications with other embedded computers via the car’s vehicle bus (Controller Area Network) and to have a high number (hundreds) of low-speed I/Os. As the second contribution, I propose a methodology to assess the error recovery system’s effects on mixed-criticality applications regarding deadline misses. The system runs two tasks: a critical airplane longitudinal control and a non-critical image compression algorithm. I start by presenting the approach on a benchmark application containing an instrumented bug into the lower criticality task; then, we improved it by injecting random errors inside the lower criticality task’s memory space through a debugger. In the latter case, thanks to the HIL, it is possible to pause the time domain simulation when the debugger operates and resume it once the injection is complete. In this way, it is possible to interact with the target without interfering with the simulation results, combining a full control of the target with an accurate time-domain assessment. The last contribution of this third group is about a methodology to verify, on multi-agent robots, the synchronization between two agents in charge to move the end effector of a delta robot: the correct position and speed of the end effector at any time is strongly affected by a loss of synchronization. The last two contributions may seem unrelated to the automotive industry, but interest in these applications is gaining. Mixed-criticality systems allow reducing the number of ECUs inside cars (for cost reduction), while the multi-agent approach is helpful to improve the cooperation of the connected cars with respect to other vehicles and the infrastructure. The fourth contribution, contained in the appendix, is about a machine learning application to improve the social acceptance of autonomous vehicles. The idea is to improve the comfort of the passengers by recognizing their emotions. I started with the idea to modify the vehicle’s driving style based on a real-time emotions recognition system but, due to the difficulties of performing such operations in an experimental setup, I move to analyze them offline. The emotions are determined on volunteers’ facial expressions recorded while viewing 3D representa- tions showing different calibrations. Thanks to the passengers’ emotional responses, it is possible to choose the better calibration from the comfort point of view