Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

MiniCPS: A toolkit for security research on CPS Networks

In recent years, tremendous effort has been spent to modernizing communication infrastructure in Cyber-Physical Systems (CPS) such as Industrial Control Systems (ICS) and related Supervisory Control and Data Acquisition (SCADA) systems. While a great amount of research has been conducted on network security of office and home networks, recently the security of CPS and related systems has gained a lot of attention. Unfortunately, real-world CPS are often not open to security researchers, and as a result very few reference systems and topologies are available. In this work, we present MiniCPS, a CPS simulation toolbox intended to alleviate this problem. The goal of MiniCPS is to create an extensible, reproducible research environment targeted to communications and physical-layer interactions in CPS. MiniCPS builds on Mininet to provide lightweight real-time network emulation, and extends Mininet with tools to simulate typical CPS components such as programmable logic controllers, which use industrial protocols (Ethernet/IP, Modbus/TCP). In addition, MiniCPS defines a simple API to enable physical-layer interaction simulation. In this work, we demonstrate applications of MiniCPS in two example scenarios, and show how MiniCPS can be used to develop attacks and defenses that are directly applicable to real systems.Comment: 8 pages, 6 figures, 1 code listin

A proposal to introduce digitalization technologies within the automation learning process

Although the digital factory (DF) concept has raised high expectations since its inception, it is still missing industrial impact. One of the problems attributed to this issue is the lack of education curricula for enhancing the related digital competences of the future professionals. Higher education institutions, as major stakeholders in education, should introduce the new technologies for DF in practical courses. However, it is difficult to deal with the complexity of those technologies in a time-limited environment such us a bachelor or a master course. Instead of providing complete knowledge, this paper proposes to focus on the methodological aspects that allow students to acquire the skills needed to handle those technologies. Specifically, this paper illustrates this approach for teaching virtual commissioning (VC) within the automation learning process. The goal is to show the students how to use powerful industrial tools for performing VC through a set of methodological steps that help students manage the complexity of the VC process regardless of the specific tools used for it.This work was financed by Erasmus+, UE (grant number 2018-1-FR01-KA203-048175) and by GV/EJ (grant numbers IT1324-19 and KK-2019-00095

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low-cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the mesoscale features, small cross-sections and complex geometries were considered the main problems. For both processing methods, fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed

A Hardware-in-the-Loop Facility for Integrated Vehicle Dynamics Control System Design and Validation

Due to the increased number and the complexity of the embedded systems in today’s vehicle, there is ever increasing pressure to reduce the development cost and time to market of such systems. In recent years, Model based Development (MBD) is becoming a main stream in the development of automotive embedded systems, and Hardware-in-the-Loop (HiL) testing is one of the key steps toward the implementation of MBD approach. This paper presents the recent HiL facility that has been developed at Cranfield University. The HiL setup includes real steering and brake smart actuator, high fidelity validated vehicle model, complete rapid control prototyping tool chain, and driver-in-the-loop capability. The applications of HiL setup are including but not limited to: smart actuators system identification; rapid control development and early validation of standalone and/or integrated vehicle dynamics control systems. Furthermore, the facility can be employed for investigation on driver-vehicle interaction at the presence of standalone active steering and/or brake systems as well as various Advanced Driver Assist Systems (ADAS), such as lane keeping or adaptive cruise control systems. The capability of the HiL facility for validation of a several newly developed vehicle dynamics control systems is presente

Reducing risk in pre-production investigations through undergraduate engineering projects.

This poster is the culmination of final year Bachelor of Engineering Technology (B.Eng.Tech) student projects in 2017 and 2018. The B.Eng.Tech is a level seven qualification that aligns with the Sydney accord for a three-year engineering degree and hence is internationally benchmarked. The enabling mechanism of these projects is the industry connectivity that creates real-world projects and highlights the benefits of the investigation of process at the technologist level. The methodologies we use are basic and transparent, with enough depth of technical knowledge to ensure the industry partners gain from the collaboration process. The process we use minimizes the disconnect between the student and the industry supervisor while maintaining the academic freedom of the student and the commercial sensitivities of the supervisor. The general motivation for this approach is the reduction of the entry cost of the industry to enable consideration of new technologies and thereby reducing risk to core business and shareholder profits. The poster presents several images and interpretive dialogue to explain the positive and negative aspects of the student process