Design and discrete event simulation of power and free handling systems

Effective manufacturing systems design and implementation has become increasingly critical, with the reduction in manufacturing product lead times, and the subsequent influence on engineering projects. Tools and methodologies that can assist the design team must be both manageable and efficient to be successful. Modelling, using analytical and mathematical models, or using computer assisted simulations, are used to accomplish design objectives. This thesis will review the use of analytical and discrete event computer simulation models, applied to the design of automated power and free handling systems, using actual case studies to create and support a practical approach to design and implementation of these types of systems. The IDEF process mapping approach is used to encompass these design tools and system requirements, to recommend a generic process methodology for power and free systems design. The case studies consisted of three actual installations within the Philips Components Ltd facility in Durham, a manufacturer of television tubes. Power and free conveyor systems at PCL have assumed increased functions from the standard conveyor systems, ranging from stock handling and buffering, to type sorting and flexible product routing. In order to meet the demands of this flexible manufacturing strategy, designing a system that can meet the production objectives is critical. Design process activities and engineering considerations for the three projects were reviewed and evaluated, to capture the generic methodologies necessary for future design success. Further, the studies were intended to identify both general and specific criteria for simulating power and free conveyor handling systems, and the ingredients necessary for successful discrete event simulation. The automated handling systems were used to prove certain aspects of building, using and analysing simulation models, in relation to their anticipated benefits, including an evaluation of the factors necessary to ensure their realisation. While there exists a multitude of designs for power and free conveyor systems based on user requirements and proprietary equipment technology, the principles of designing and implementing a system can remain generic. Although specific technology can influence detailed design, a common, consistent approach to design activities was a proven requirement In all cases. Additionally, it was observed that no one design tool was sufficient to ensure maximum system success. A combination of both analytical and simulation methods was necessary to adequately optimise the systems studied, given unique and varying project constraints. It followed that the level of application of the two approaches was directly dependent on the initial engineering project objectives, and the ability to accurately identify system requirements

Analysis And Simulation Tools For Solar Array Power Systems

This dissertation presents simulation tools developed specifically for the design of solar array power systems. Contributions are made in several aspects of the system design phases, including solar source modeling, system simulation, and controller verification. A tool to automate the study of solar array configurations using general purpose circuit simulators has been developed based on the modeling of individual solar cells. Hierarchical structure of solar cell elements, including semiconductor properties, allows simulation of electrical properties as well as the evaluation of the impact of environmental conditions. A second developed tool provides a co-simulation platform with the capability to verify the performance of an actual digital controller implemented in programmable hardware such as a DSP processor, while the entire solar array including the DC-DC power converter is modeled in software algorithms running on a computer. This virtual plant allows developing and debugging code for the digital controller, and also to improve the control algorithm. One important task in solar arrays is to track the maximum power point on the array in order to maximize the power that can be delivered. Digital controllers implemented with programmable processors are particularly attractive for this task because sophisticated tracking algorithms can be implemented and revised when needed to optimize their performance. The proposed co-simulation tools are thus very valuable in developing and optimizing the control algorithm, before the system is built. Examples that demonstrate the effectiveness of the proposed methodologies are presented. The proposed simulation tools are also valuable in the design of multi-channel arrays. In the specific system that we have designed and tested, the control algorithm is implemented on a single digital signal processor. In each of the channels the maximum power point is tracked individually. In the prototype we built, off-the-shelf commercial DC-DC converters were utilized. At the end, the overall performance of the entire system was evaluated using solar array simulators capable of simulating various I-V characteristics, and also by using an electronic load. Experimental results are presented

Integrating computer-aided modeling and micro-simulation in multi-criteria evaluation of service infrastructure assignment approaches

Purpose: This paper proposes an integrated computer-supported multi-staged approach to the flexible design and multicriteria evaluation of service infrastructure assignment processes/ algorithms. Design/methodology/approach: It involves particularizing a metamodel encompassing the main generic components and relationships into process models and process instances, by incorporating structural data from the real-life system. Existing data on the target user population is fed into a micro-modeling system to generate a matching population of individual “virtual” users, each with its own set of trait values. The micro-simulation of their interaction with the assignment process of both the incumbent and the competitors generates a rich multi-dimensional output, encompassing both “revealed” and non-observable data. This enables a comprehensive multi-criteria evaluation of the foreseeable performance of the designed process/ algorithm, and therefore its iterative improvement. Findings: The research project developed a set of methodologies and associated supporting tools encompassing the modeling, micro-simulation and performance assessment of service infrastructure assignment processes. Originality/value: The proposed approach facilitates, in a multicriteria environment, the flexible modeling/design of situation-specific assignment processes/algorithms and their performance assessment when facing their case-specific user populationPeer Reviewe

Design Space Exploration in Cyber-Physical Systems

Cyber physical systems (CPS) integrate a variety of engineering areas such as control, mechanical and computer engineering in a holistic design effort. While interdependencies between the different disciplines are key attributes of CPS design science, little is known about the impact of design decisions of the cyber part on the overall system qualities. To investigate these interdependencies, this paper proposes a simulation-based Design Space Exploration (DSE) framework that considers detailed cyber system parameters such as cache size, bus width, and voltage levels in addition to physical and control parameters of the CPS. We propose an exploration algorithm that surfs the parameter configurations in the cyber physical sub-systems, in order to approximate the Pareto-optimal design points with regards to the trade-os among the design objectives, such as energy consumption and control stability. We apply the proposed framework to a network control system for an inverted-pendulum application. The presented holistic evaluation of the identified Pareto-points reveals the presence of non-trivial trade-os, which are imposed by the control, physical, and detailed cyber parameters. For instance the identified energy and control optimal design points comprise configurations with a wide range of CPU speeds, sample times and cache configuration following non-trivial zig-zag patterns. The proposed framework could identify and manage those trade-os and, as a result, is an imperative rst step to automate the search for superior CSP configurations

Experimental analysis of computer system dependability

This paper reviews an area which has evolved over the past 15 years: experimental analysis of computer system dependability. Methodologies and advances are discussed for three basic approaches used in the area: simulated fault injection, physical fault injection, and measurement-based analysis. The three approaches are suited, respectively, to dependability evaluation in the three phases of a system's life: design phase, prototype phase, and operational phase. Before the discussion of these phases, several statistical techniques used in the area are introduced. For each phase, a classification of research methods or study topics is outlined, followed by discussion of these methods or topics as well as representative studies. The statistical techniques introduced include the estimation of parameters and confidence intervals, probability distribution characterization, and several multivariate analysis methods. Importance sampling, a statistical technique used to accelerate Monte Carlo simulation, is also introduced. The discussion of simulated fault injection covers electrical-level, logic-level, and function-level fault injection methods as well as representative simulation environments such as FOCUS and DEPEND. The discussion of physical fault injection covers hardware, software, and radiation fault injection methods as well as several software and hybrid tools including FIAT, FERARI, HYBRID, and FINE. The discussion of measurement-based analysis covers measurement and data processing techniques, basic error characterization, dependency analysis, Markov reward modeling, software-dependability, and fault diagnosis. The discussion involves several important issues studies in the area, including fault models, fast simulation techniques, workload/failure dependency, correlated failures, and software fault tolerance

A design-for-casting integrated approach based on rapid simulation and modulus criterion

This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed