An Integrated Environment for the Design and Control of Deadlock-Free Flexible Manufacturing Cells

2004 ◽  
Author(s):  
Chengyin Yuan ◽  
Placid Ferreira
Keyword(s):  
Rapid Prototyping ◽  
Flexible Manufacturing ◽  
Low Cost ◽  
Work Force ◽  
Shop Floor ◽  
Manufacturing Cells ◽  
Manufacturing Enterprise ◽  
Function Blocks ◽  
And Control ◽  
Iec 61499

At the enterprise level, manufacturing organizations are faced with accelerating technological cycles, global competition and an increasingly mobile work force. The flexibility of the enterprise and its ability to respond to various customer demands governs the competitiveness of the enterprise to the changes in its market and in the society in which it operates. It has been recognized for many years that flexibility on the enterprise floor can always be achieved if the resulting cost of product and process changeovers and its operations are not considered. However, with the increasing competitive pressures on today’s manufacturing enterprise, a flexible-manufacturing environment must be achieved at relatively low cost and high work-force productivity while maintaining a competitive advantage. To accomplish this goal, the manufacturing enterprise must be able to be reconfigured and verified with an increased level of automation that is scalable and flexible to meet diverse product demands quickly and economically. In this paper, we will introduce the recent research work on developing an integrated rapid prototyping environment, EMBench [22, 23], which can provide design, control configuration, simulation and deployment services for flexible manufacturing systems. This rapid prototyping environment has its own user-friendly GUI (Graphical User Interface) that allows user to issue various commands to the controller at different layers, from the simple joint servo to the complex manufacturing cell. In this paper, we also propose the implementation diagram for the controller of manufacturing cells that consists of scheduler, dispatcher, real-time database and structural control policy. All these internal components are responsible for storing system configuration, optimizing processing plan, releasing appropriate command, etc. We also present the idea of cell model and explore its characteristics and behaviors as well as the resource and workstation models. All above modules and architecture are developed using IEC-61499 function blocks that support scalable expansion and modular design. To demonstrate our theoretical achievements, we have developed various IEC-61499 function blocks to integrate various resources on the enterprise shop floor and achieve flexibility at a low cost. This software environment facilitates a modular, component-based mechanical and control design, simulating and prototyping tool for shop floor control.

An Integrated Rapid Prototyping Environment for Reconfigurable Manufacturing Systems

Materials ◽  
2003 ◽  
Author(s):  
Chengyin Yuan ◽  
Placid Ferreira
Keyword(s):  
Manufacturing Systems ◽  
Modular Design ◽  
Low Cost ◽  
Work Force ◽  
Shop Floor ◽  
Reconfigurable Manufacturing Systems ◽  
Reconfigurable Manufacturing ◽  
Manufacturing Enterprise ◽  
Function Blocks ◽  
Iec 61499

At the enterprise level, manufacturing organizations are faced with accelerating technological cycles, global competition and an increasingly mobile work force. The flexibility of an enterprise and its ability to respond to new customer demands governs the competitiveness of the enterprise to changes in its market and in the society in which it operates. The flexibility in production processes must be able to accommodate differing product mixes with the changing availability of a skilled work force. It has been recognized for many years that flexibility on the enterprise shop floor can always be achieved if the resulting cost of product, process and system changeovers are not considered. However, with the increasing competitive pressures on today’s manufacturing enterprise; a highly flexible and reconfigurable manufacturing environment must be achieved at relatively low cost and high work-force productivity while maintaining a competitive advantage. To accomplish this goal the manufacturing enterprise must be able to be reconfigured with an increased level of automation that is scalable and flexible to meet diverse product demands. In this paper, we will introduce EMBench as the design and simulation environment for reconfigurable manufacturing systems. This environment provides a universal GUI (Graphical User Interface) that allows user to design, configure and simulate various resources on the shop floor level. In this paper, we present the resource model, workstation model and cell model and explore their characteristics and behaviors. We also propose the general interface for different models using IEC-61499 function blocks that allow scalable expansion and modular design. We use IEC-61499 function blocks and a service layer architecture to integrate various resources on the enterprise shop floor and achieve flexibility at a low cost. This environment facilitates a modular, component-based design of services for enterprise shop floor control.

EMBench: A Rapid Prototyping Environment for Numerical Control Systems

2002 ◽  
Author(s):  
Sachin Jain ◽  
Chengyin Yuan ◽  
Placid Ferreira
Keyword(s):  
Rapid Prototyping ◽  
Control Systems ◽  
Control Design ◽  
Numerical Control ◽  
Automation Systems ◽  
Function Blocks ◽  
Trajectory Interpolation ◽  
And Control ◽  
Iec 61499 ◽  
Modular Component

In this paper we describe an environment for performing both mechanical and control design for flexible automation systems. The environment provides a means of layering and encapsulating services so that complex multi-axis numerical control systems can be configured, detailed electromechanical simulations performed and then deployed. The system uses IEC-61499 as a means for modularization and reuse of implemented control services. Using IEC-61499 function blocks and a service-layer architecture, control services ranging for basic servoing of a joint, to kinematic co-ordination of joints of a mechanism, to trajectory interpolation, to language parsing and HMI processing, can be configured for an application. The environment facilitates a modular, component-based design of services for numerical control systems.

A Data-Driven Simulation-Based Optimisation Approach for Adaptive Scheduling and Control of Dynamic Manufacturing Systems

2016 ◽  
Vol 1140 ◽  
pp. 449-456 ◽  
Author(s):  
Mirko Kück ◽  
Jens Ehm ◽  
Michael Freitag ◽  
Enzo M. Frazzon ◽  
Ricardo Pimentel
Keyword(s):  
Simulation Model ◽  
Real Time ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Shop Floor ◽  
Time Data ◽  
Rush Order ◽  
Real Time Data ◽  
High Flexibility ◽  
And Control

The increasing customisation of products, which leads to higher numbers of product variants with smaller lot sizes, requires a high flexibility of manufacturing systems. These systems are subject to dynamic influences and need increasing effort for the generation of the production schedules and for the control of the processes. This paper presents an approach that addresses these challenges. First, scheduling is done by coupling an optimisation heuristic with a simulation model to handle complex and stochastic manufacturing systems. Second, the simulation model is continuously adapted by real-time data from the shop floor. If, e.g., a machine breakdown or a rush order appears, the simulation model and consequently the scheduling model is updated and the optimisation heuristic adjusts an existing schedule or generates a new one. This approach uses real-time data provided by future cyber-physical systems to integrate scheduling and control and to manage the dynamics of highly flexible manufacturing systems.

Low-Cost Embedded System for Shop Floor Communications and Control Based on OPC-UA

2019 ◽  
pp. 3-12
Author(s):  
Hector F. Bano ◽  
Carlos A. Garcia ◽  
Andres Cabrera A ◽  
Esteban X. Castellanos ◽  
Jose E. Naranjo ◽  
...  
Keyword(s):  
Embedded System ◽  
Low Cost ◽  
Shop Floor ◽  
And Control

Wireless Control Model Based on Rapid Prototyping Equipments

2010 ◽  
Vol 44-47 ◽  
pp. 51-55
Author(s):  
Yi Na Guo ◽  
Yong Tang Li
Keyword(s):  
Rapid Prototyping ◽  
Low Cost ◽  
Network Control ◽  
Serial Interface ◽  
Design Choice ◽  
Control Centre ◽  
Network Control Systems ◽  
Software And Hardware ◽  
High Level ◽  
And Control

Traditional network control systems require designers to use the serial interface or the bus as tools to control equipments. These ways lead to complicated circuit connection and unreliability of hardware. It is therefore imperative to have good methods to explore a more suitable design choice, which can avoid the problems mentioned above as more as possible. This paper presents a TD-SCDMA network control system based on rapid prototyping equipment in VC++ 2008. It also provides high-level modelling, programming methods and running results for this system in terms of software and hardware. More specifically, this system takes advantage of network control technology, TD-SCDMA network technology and advanced manufacturing technology. Wireless communication and control are accomplished timely and accurately between the network control centre and a number of controlled equipments by use of Winsock control in TD-SCDMA network. This system also can manage the historical data by using database. Furthermore, it has such advantages as low cost and easy to maintain and promote.

Optimal Machining Parameter Selection Based on Real-Time Machine Monitoring Using IEC 61499 Function Blocks for Use in a Cloud Manufacturing Environment: A Case Study for Face Milling

2014 ◽  
Author(s):  
Nikolaos Tapoglou ◽  
Jörn Mehnen ◽  
Michael Doukas ◽  
Dimitris Mourtzis
Keyword(s):  
Cloud Manufacturing ◽  
Face Milling ◽  
Simulation Software ◽  
Machining Process ◽  
Shop Floor ◽  
Manufacturing Environment ◽  
Function Blocks ◽  
Machining Parameter ◽  
Iec 61499

Optimization of manufacturing processes is one of the key challenges towards a sustainable manufacturing environment. The components manufactured nowadays are usually divided into small batches of highly customized parts. These parts are usually machined using the traditional approach for machining on CNC machines. This approach involves the creation of a static G-code for every component that is manufactured, which is dispatched to the machines either manually or through a LAN network. In this paper a new approach in machine tool programming is presented. The proposed system is based on IEC 61499 function blocks to create last-minute feature based code for machining respecting actual machine status. The proposed system optimizes cutting parameters and delivers optimized code with respect to machining time. The function block approach is ideal for on-controller implementation while also allowing through its web based option the embedding into a cloud manufacturing environment. A cloud platform accommodates the machine availability monitoring module for increasing shop-floor awareness and allowing for the correct decisions at the right time. The machining process of face milling was selected as a case study for demonstrating the functionality of the proposed system. The results of the case study are visualized and verified using simulation software.

Sign in / Sign up

Export Citation Format

Share Document