Development of a reconfigurable assembly system with enhanced control capabilities and virtual commissioning

Thesis (M. Tech. (Engineering: Electrical)) -- Central University of technology, Free State, 2013The South African (SA) manufacturing industry requires developing similar levels of sophistication and expertise in automation as its international rivals to compete for global markets. To achieve this, manufacturing plants need to be managed extremely efficiently to ensure the quality of manufactured products and these plants must also have the relevant infrastructure. Furthermore, this industry must also compensate for rapid product introduction, product changes and short product lifespan. To support this need, this industry must engage in the current trend in automation known as reconfigurable manufacturing. The aim of the study is to develop a reconfigurable assembly system with enhanced control capabilities by utilizing virtual commissioning. In addition, this system must be capable of assembling multiple different products of a product range; reconfigure to accommodate the requirements of these products; autonomously reroute the product flow and distribute workload among assembly cells; handle erroneous products; and implement enhanced control methods. To achieve this, a literature study was done to confirm the type of components to be used, reveal design issues and what characteristics such a system must adhere to. Software named DELMIA was used to create a virtual simulation environment to verify the system and simultaneously scrutinize the methods of verification. On completion, simulations were conducted to verify software functions, device movements and operations, and the control software of the system. Based on simulation results, the physical system was built, and then verified with a multi agent system as overhead control to validate the entire system. The final results showed that the project objectives are achievable and it was also found that DELMIA is an excellent tool for system verification and will expedite the design of a system. By obtaining these results it is indicated that companies can design and verify their systems earlier through virtual commissioning. In addition, their systems will be more flexible, new products or product changes can be introduced more frequently, with minimum cost and downtime. This will enable SA manufacturing companies to be more competitive, ensure increased productivity, save time and so ensure them an advantage over their international competition

Development of a Hybrid Control and Monitoring System within a Reconfigurable Assembly System

Published ThesisExpanding global markets are constantly changing and unstable. South African manufacturing companies need to develop similar levels of sophistication and expertise in the automation industry as its international rivals, to compete for these markets and meet rising consumer expectations. To remain competitive, these manufacturing companies must manage their plants extremely efficiently to ensure the quality of assembled products; allow for rapid product introduction and product changes; achieve shortened throughput cycles; ensure more reliable delivery dates; and effectively coordinate product demand while contending with decreased product lifespans. To accomplish this, manufacturing companies in SA are progressively engaging in the current trend in automation known as reconfigurable manufacturing. Due to the extreme flexibility of these reconfigurable systems, the monitor and control systems for these require the same levels of flexibility. The purpose of the study is to develop a hybrid control and monitoring system, to supervise and control reconfigurable assembly systems (RAS), and adapt to the flexibility of these systems. To achieve this, a literature study was done in the research area to reveal the prerequisites for such systems; the physical assembly devices were designed and built; the separate software modules developed and ultimately integrated into the intended system. The tests to validate the system were developed in such a way that each subsection of the system is validated by using a different system software function. This inevitably confirms the functionality of the fundamental components and the system in entirety. The results indicated that devices are easily added to the system; devices are successfully detected and identified; how the system plans production, and how the system automatically configures itself. Further results showed the capability of the system to generate and virtually wire system runtime code; store and retrieve production data; as well as warn and alarm on unwanted conditions. By obtaining these results, companies can configure their systems with ease, in a shorter amount of time, and without any human error. Moreover, their systems will be more flexible, allow easy addition of new products and assembly devices, and with minimal downtime. This will enable SA manufacturing companies to be more competitive, ensure increased productivity, achieve extreme system flexibility, and decrease lead times – thus ensuring them an advantage over their international competitors

Virtual commissioning: A tool to ensure effective system integration

Confeence ProceedingsSouth African industry today need to utilise the available technology across disciplines to compete globally. One of the latest trends in the system integration field is to use virtual commissioning. Virtual commissioning allow the developer to validate the complete operation of new systems before anything materialise in the physical environment. It does not only allow operation verification but also informs the validation of the physical layout and architecture of the system in development. Virtual commissioning even allow verification of system code and rectification of design flaws. The paper will show with a suitable case study how it is possible to predict the functionality of a system with early verification of system code from your desktop. This will give companies the competitive advantage due to complete system verification and validation before any mayor capital layout

A stable isotope assay with 13C-labeled polyethylene to investigate plastic mineralization mediated by Rhodococcus ruber

Methods that unambiguously prove microbial plastic degradation and allow for quantification of degradation rates are necessary to constrain the influence of microbial degradation on the marine plastic budget. We developed an assay based on stable isotope tracer techniques to determine microbial plastic mineralization rates in liquid medium on a lab scale. For the experiments, 13C-labeled polyethylene (13C-PE) particles (irradiated with UV-light to mimic exposure of floating plastic to sunlight) were incubated in liquid medium with Rhodococcus ruber as a model organism for proof of principle. The transfer of 13C from 13C-PE into the gaseous and dissolved CO2 pools translated to microbially mediated mineralization rates of up to 1.2 % yr−1 of the added PE. After incubation, we also found highly 13C-enriched membrane fatty acids of R. ruber including compounds involved in cellular stress responses. We demonstrated that isotope tracer techniques are a valuable tool to detect and quantify microbial plastic degradation

PIRCHE-II is related to graft failure after kidney transplantation

Individual HLA mismatches may differentially impact graft survival after kidney transplantation. Therefore, there is a need for a reliable tool to define permissible HLA mismatches in kidney transplantation. We previously demonstrated that donor-derived Predicted Indirectly ReCognizable HLA Epitopes presented by recipient HLA class II (PIRCHE-II) play a role in de novo donor-specific HLA antibodies formation after kidney transplantation. In the present Dutch multi-center study, we evaluated the possible association between PIRCHE-II and kidney graft failure in 2,918 donor-recipient couples that were transplanted between 1995 and 2005. For these donors-recipients couples, PIRCHE-II numbers were related to graft survival in univariate and multivariable analyses. Adjusted for confounders, the natural logarithm of PIRCHE-II was associated with a higher risk for graft failure [hazard ratio (HR): 1.13, 95% CI: 1.04-1.23, p = 0.003]. When analyzing a subgroup of patients who had their first transplantation, the HR of graft failure for ln(PIRCHE-II) was higher compared with the overall cohort (HR: 1.22, 95% CI: 1.10-1.34, p < 0.001). PIRCHE-II demonstrated both early and late effects on graft failure in this subgroup. These data suggest that the PIRCHE-II may impact graft survival after kidney transplantation. Inclusion of PIRCHE-II in donor-selection criteria may eventually lead to an improved kidney graft survival

PIRCHE-II Is Related to Graft Failure after Kidney Transplantation

Individual HLA mismatches may differentially impact graft survival after kidney transplantation. Therefore, there is a need for a reliable tool to define permissible HLA mismatches in kidney transplantation. We previously demonstrated that donor-derived Predicted Indirectly ReCognizable HLA Epitopes presented by recipient HLA class II (PIRCHE-II) play a role in de novo donor-specific HLA antibodies formation after kidney transplantation. In the present Dutch multi-center study, we evaluated the possible association between PIRCHE-II and kidney graft failure in 2,918 donor–recipient couples that were transplanted between 1995 and 2005. For these donors–recipients couples, PIRCHE-II numbers were related to graft survival in univariate and multivariable analyses. Adjusted for confounders, the natural logarithm of PIRCHE-II was associated with a higher risk for graft failure [hazard ratio (HR): 1.13, 95% CI: 1.04–1.23, p = 0.003]. When analyzing a subgroup of patients who had their first transplantation, the HR of graft failure for ln(PIRCHE-II) was higher compared with the overall cohort (HR: 1.22, 95% CI: 1.10–1.34, p &lt; 0.001). PIRCHE-II demonstrated both early and late effects on graft failure in this subgroup. These data suggest that the PIRCHE-II may impact graft survival after kidney transplantation. Inclusion of PIRCHE-II in donor-selection criteria may eventually lead to an improved kidney graft survival

T-Cell Epitopes Shared Between Immunizing HLA and Donor HLA Associate With Graft Failure After Kidney Transplantation

CD4(+) T-helper cells play an important role in alloimmune reactions following transplantation by stimulating humoral as well as cellular responses, which might lead to failure of the allograft. CD4(+) memory T-helper cells from a previous immunizing event can potentially be reactivated by exposure to HLA mismatches that share T-cell epitopes with the initial immunizing HLA. Consequently, reactivity of CD4(+) memory T-helper cells toward T-cell epitopes that are shared between immunizing HLA and donor HLA could increase the risk of alloimmunity following transplantation, thus affecting transplant outcome. In this study, the amount of T-cell epitopes shared between immunizing and donor HLA was used as a surrogate marker to evaluate the effect of donor-reactive CD4(+) memory T-helper cells on the 10-year risk of death-censored kidney graft failure in 190 donor/recipient combinations using the PIRCHE-II algorithm. The T-cell epitopes of the initial theoretical immunizing HLA and the donor HLA were estimated and the number of shared PIRCHE-II epitopes was calculated. We show that the natural logarithm-transformed PIRCHE-II overlap score, or Shared T-cell EPitopes (STEP) score, significantly associates with the 10-year risk of death-censored kidney graft failure, suggesting that the presence of pre-transplant donor-reactive CD4(+) memory T-helper cells might be a strong indicator for the risk of graft failure following kidney transplantation