Smart technologies for effective reconfiguration: the FASTER approach

Current and future computing systems increasingly require that their functionality stays flexible after the system is operational, in order to cope with changing user requirements and improvements in system features, i.e. changing protocols and data-coding standards, evolving demands for support of different user applications, and newly emerging applications in communication, computing and consumer electronics. Therefore, extending the functionality and the lifetime of products requires the addition of new functionality to track and satisfy the customers needs and market and technology trends. Many contemporary products along with the software part incorporate hardware accelerators for reasons of performance and power efficiency. While adaptivity of software is straightforward, adaptation of the hardware to changing requirements constitutes a challenging problem requiring delicate solutions. The FASTER (Facilitating Analysis and Synthesis Technologies for Effective Reconfiguration) project aims at introducing a complete methodology to allow designers to easily implement a system specification on a platform which includes a general purpose processor combined with multiple accelerators running on an FPGA, taking as input a high-level description and fully exploiting, both at design time and at run time, the capabilities of partial dynamic reconfiguration. The goal is that for selected application domains, the FASTER toolchain will be able to reduce the design and verification time of complex reconfigurable systems providing additional novel verification features that are not available in existing tool flows

Deployment of an Distributed Strategic Material Flow Control for Automated Material Flow Systems Consisting of Autonomous Modules

The modularisation of hardware and software is one approach to handle the demand for increasing flexibility and changeability of automated material flow systems that are, for example, utilised in flexible production systems. In such automated material flow systems, autonomous modules communicate with each other to coordinate and execute transport tasks. In this paper a strategic material flow control is introduced, which is distributed on several modules realised with a multi-agent system. The strategic material flow control agent coordinates transport tasks with advanced logistical requirements, such as sequencing. A transport task states for a transport unit the system source and sink together with arrival criteria at the sink, e.g. sequence In order to fulfil the arrival criteria the strategic material flow agent selects additional destinations within the automated material flow system to buffer a transport unit. For the selection of suitable buffer modules, several strategies are proposed and evaluated in a simulation study

Enhanced integrated modelling approach to reconfiguring manufacturing enterprises

Dynamism and uncertainty are real challenges for present day manufacturing enterprises (MEs). Reasons include: an increasing demand for customisation, reduced time to market, shortened product life cycles and globalisation. MEs can reduce competitive pressure by becoming reconfigurable and change-capable. However, modern manufacturing philosophies, including agile and lean, must complement the application of reconfigurable manufacturing paradigms. Choosing and applying the best philosophies and techniques is very difficult as most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of changing and distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change future MEs. This thesis, titled Enhanced Integrated Modelling Approach to Reconfiguring Manufacturing Enterprises , introduces the development and prototyping a model-driven environment for the design, engineering, optimisation and control of the reconfiguration of MEs with an embedded capability to handle various types of change. The thesis describes a novel systematic approach, namely enhanced integrated modelling approach (EIMA), in which coherent sets of integrated models are created that facilitates the engineering of MEs especially their production planning and control (PPC) systems. The developed environment supports the engineering of common types of strategic, tactical and operational processes found in many MEs. The EIMA is centred on the ISO standardised CIMOSA process modelling approach. Early study led to the development of simulation models during which various CIMOSA shortcomings were observed, especially in its support for aspects of ME dynamism. A need was raised to structure and create semantically enriched models hence forming an enhanced integrated modelling environment. The thesis also presents three industrial case examples: (1) Ford Motor Company; (2) Bradgate Furniture Manufacturing Company; and (3) ACM Bearings Company. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of any target organisation need to be modelled. Coherent multi-perspective case study models are presented that have facilitated process reengineering and associated resource system configuration. Such models have a capability to enable PPC decision making processes in support of the reconfiguration of MEs. During these case studies, capabilities of a number of software tools were exploited such as Arena®, Simul8®, Plant Simulation®, MS Visio®, and MS Excel®. Case study results demonstrated effectiveness of the concepts related to the EIMA. The research has resulted in new contributions to knowledge in terms of new understandings, concepts and methods in following ways: (1) a structured model driven integrated approach to the design, optimisation and control of future reconfiguration of MEs. The EIMA is an enriched and generic process modelling approach with capability to represent both static and dynamic aspects of an ME; and (2) example application cases showing benefits in terms of reduction in lead time, cost and resource load and in terms of improved responsiveness of processes and resource systems with a special focus on PPC; (3) identification and industrial application of a new key performance indicator (KPI) known as P3C the measuring and monitoring of which can aid in enhancing reconfigurability and responsiveness of MEs; and (4) an enriched modelling concept framework (E-MUNE) to capture requirements of static and dynamic aspects of MEs where the conceptual framework has the capability to be extended and modified according to the requirements. The thesis outlines key areas outlining a need for future research into integrated modelling approaches, interoperation and updating mechanisms of partial models in support of the reconfiguration of MEs

Reconfigurable production control systems: beyond ADACOR

In the recent evolution of production control systems, the emergence of decentralized systems capable of dealing with the rapid changes in the production environment better than the traditional centralized architectures has been one of the most significant developments. The agent-based and holonic paradigms symbolize this approach, and ADACOR holonic control architecture is a successful example of such a system. In this paper, authors discusses the current challenges and the way to go in the direction of new, reconfigurable, evolvable and ubiquitous systems, able to respond to current production environment demands and variability

Reconfigurable and transportable container-integrated production system

In this paper, the concept and the prototype realization of a novel reconfigurable small-footprint manufacturing system in a transportable container is presented. The containerized format enables transportation of the system to provide on-site manufacturing, enabling the benefits of localized service delivery without duplication of equipment at multiple locations. Three industrial product use cases with varying manufacturing and performance requirements were analyzed. All of the use cases demanded highly customized products with high quality in low production volumes. Based on their requirements, a general system specification was derived and used to develop a concept for the container-integrated factory. A reconfigurable, modular manufacturing system is integral to the overall container concept. Production equipment was integrated in the form of interchangeable process modules, which can be quickly connected by standard utility supply and control interfaces. A modular and self-configuring control system provides assisted production workflow programming, while a modular process chain combining Additive Manufacturing, milling, precision assembly and cleaning processes has been developed. A prototype of the container-integrated factory with reconfigurable process modules and control system has been established, with full functionality and feasibility of the system demonstrated

Literature review on the ‘Smart Factory’ concept using bibliometric tools

The objective of this paper is to depict a landscape of the scientific literature on the concept of the ‘Smart Factory’, which in recent years is gaining more and more attention from academics and practitioners because of significant innovations in the production systems within the manufacturing sector. To achieve this objective, a dynamic methodology called "Systematic Literature Network Analysis (SLNA)" has been applied. This methodology combines the Systematic Literature Review approach with the analysis of bibliographic networks. The adopted methodology allows complementing traditional content-based literature reviews by extracting quantitative information from bibliographic networks to detect emerging topics, and by revealing the dynamic evolution of the scientific production of a discipline. This dynamic analysis allowed highlighting research directions and critical areas for the development of the "Smart Factory". At the same time, it offers insights on the fields on which companies, associations, politicians and technology providers need to focus in order to allow a real transition towards the implementation of large-scale Smart Factory

Reconfigurable Computing Systems for Robotics using a Component-Oriented Approach

Robotic platforms are becoming more complex due to the wide range of modern applications, including multiple heterogeneous sensors and actuators. In order to comply with real-time and power-consumption constraints, these systems need to process a large amount of heterogeneous data from multiple sensors and take action (via actuators), which represents a problem as the resources of these systems have limitations in memory storage, bandwidth, and computational power. Field Programmable Gate Arrays (FPGAs) are programmable logic devices that offer high-speed parallel processing. FPGAs are particularly well-suited for applications that require real-time processing, high bandwidth, and low latency. One of the fundamental advantages of FPGAs is their flexibility in designing hardware tailored to specific needs, making them adaptable to a wide range of applications. They can be programmed to pre-process data close to sensors, which reduces the amount of data that needs to be transferred to other computing resources, improving overall system efficiency. Additionally, the reprogrammability of FPGAs enables them to be repurposed for different applications, providing a cost-effective solution that needs to adapt quickly to changing demands. FPGAs' performance per watt is close to that of Application-Specific Integrated Circuits (ASICs), with the added advantage of being reprogrammable. Despite all the advantages of FPGAs (e.g., energy efficiency, computing capabilities), the robotics community has not fully included them so far as part of their systems for several reasons. First, designing FPGA-based solutions requires hardware knowledge and longer development times as their programmability is more challenging than Central Processing Units (CPUs) or Graphics Processing Units (GPUs). Second, porting a robotics application (or parts of it) from software to an accelerator requires adequate interfaces between software and FPGAs. Third, the robotics workflow is already complex on its own, combining several fields such as mechanics, electronics, and software. There have been partial contributions in the state-of-the-art for FPGAs as part of robotics systems. However, a study of FPGAs as a whole for robotics systems is missing in the literature, which is the primary goal of this dissertation. Three main objectives have been established to accomplish this. (1) Define all components required for an FPGAs-based system for robotics applications as a whole. (2) Establish how all the defined components are related. (3) With the help of Model-Driven Engineering (MDE) techniques, generate these components, deploy them, and integrate them into existing solutions. The component-oriented approach proposed in this dissertation provides a proper solution for designing and implementing FPGA-based designs for robotics applications. The modular architecture, the tool 'FPGA Interfaces for Robotics Middlewares' (FIRM), and the toolchain 'FPGA Architectures for Robotics' (FAR) provide a set of tools and a comprehensive design process that enables the development of complex FPGA-based designs more straightforwardly and efficiently. The component-oriented approach contributed to the state-of-the-art in FPGA-based designs significantly for robotics applications and helps to promote their wider adoption and use by specialists with little FPGA knowledge