Author supplied: Abstract—The growing importance and impact of new technologies are changing many industries. This effect is especially noticeable in the manufacturing industry. This paper explores a practical implementation of a hybrid architecture for the newest generation of manufacturing systems. The papers starts with a proposition that envisions reconfigurable systems that work together autonomously to create Manufacturing as a Service (MaaS). It introduces a number of problems in this area and shows the requirements for an architecture that can be the main research platform to solve a number of these problems, including the need for safe and flexible system behaviour and the ability to reconfigure with limited interference to other systems within the manufacturing environment. The paper highlights the infrastructure and architecture itself that can support the requirements to solve the mentioned problems in the future. A concept system named Grid Manufacturing is then introduced that shows both the hardware and software systems to handle the challenges. The paper then moves towards the design of the architecture and introduces all systems involved, including the specific hardware platforms that will be controlled by the software platform called REXOS (Reconfigurable EQuipletS Operating System). The design choices are provided that show why it has become a hybrid platform that uses Java Agent Development Framework (JADE) and Robot Operating System (ROS). Finally, to validate REXOS, the performance is measured and discussed, which shows that REXOS can be used as a practical basis for more specific research for robust autonomous reconfigurable systems and application in industry 4.0. This paper shows practical examples of how to successfully combine several technologies that are meant to lead to a faster adoption and a better business case for autonomous and reconfigurable systems in industry.
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From the article: Manufacturing technology can improve the turnover of a company if it enables fast market introduction for volume production. Reconfigurable equipment is developed to meet the growing demand for more agile production. Modular reconfiguration, defined as changing the structure of the machine, enables larger variation of products on a single manufacturing system; these solutions are called Reconfigurable Manufacturing Systems (RMS). The quality of RMS, and the required resources to bring it to reliable production, is largely determined by a swift execution of the reconfiguration process. This paper proposes a method to compare alternatives for the ways to implement reconfiguration. Three classes of reconfiguration are defined to distinguish the impact of the proposed alternatives. The procedure uses a recently introduced index method for development of RMS process modules. This index method is based on the Axiomatic Design theory. Weighing factors are used to calculate the resources and lead time needed to implement the reconfiguration process. Application of the method leads to quick comparison of alternatives in the early stage of development. Successful execution of the method was demonstrated for the manufacturing process of a 3D measuring probe.
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One of the goals of this research is to arrive at an implementation of a CAN-bus that can be used for lab exercises in regular student courses. In this paper, an overview is given of our basic ideas concerning the CAN concept and its application to the control of a manufacturing system. This system consists of two robots, a milling machine and some transportation means. In this system, every workstation will have its own CAN controller. The concept consists of a specially designed hardware structure, embedded software for the protocol and initialisation and a high level production environment, that makes it possible to configure a production system in an easy way.
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Presented at the 11th International Conference on ICT in Education, Research and Industrial Applications: Integration, Harmonization and Knowledge Transfer Lviv, Ukraine, May 14-16, 2015. Author supplied: Abstract. User requirements and low-cost small quantity production are new challenges for the modern manufacturing industry. This means that small batch sizes or even the manufacturing of one single product should be affordable. To make such a system cost-effective it should be capable to use the available production resources for many different products in parallel. This paper gives a description of the requirements and architecture of an end-user driven production system. The end-user communicates with the production system by a web interface, so this manufacturing system can be characterized in terms of cloud comput- ing as the implementation of manufacturing as a service, abbreviated to MaaS.
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Elke periode kent zijn eigen revolutie en elke revolutie brengt zijn eigen organisatorische model met zich mee. We bevinden ons nu in de 4e industri¨ele revolutie, waar het internet van dingen ons verbindt met autonome embedded systemen. Deze systemen zijn actief in de virtuele ’cyber’ wereld, alsook in de echte ’fysieke’ wereld om ons heen. Deze zogenoemde ’Cyber-Fysieke’ Systemen volgen daarmee een modern organisatorisch model, namelijk zelfmanagement, en zijn dan ook in staat zelf proactieve acties te ondernemen. Dit proefschrift belicht productiesystemen vanuit het Cyber-Fysieke perspectief. De productiesystemen zijn hier herconfigureerbaar, autonoom en zeer flexibel. Dit kan enkel worden bereikt door het ontwikkelen van nieuwe methodes en het toepassen van nieuwe technologie¨en die flexibiliteit verder bevorderen. Echter, effici¨entie is ook van belang, bijvoorbeeld door productassemblage zo flexibel te maken dat het daardoor kosteneffici¨ent is om de productie van diverse producten met een lage oplage, zogenaamde high-mix, low volume producten, te automatiseren. De mogelijkheid om zo flexibel te kunnen produceren moet bereikt worden door de creatie van nieuwe methoden en middelen, waarbij nieuwe technologie¨en worden gecombineerd; een belangrijk aspect hierbij is dat dit toepasbaar getest moet worden door gebruik van simulatoren en speciaal hiervoor ontwikkelde productiesystemen. Dit onderzoek zal beginnen met het introduceren van het concept achter de bijbehorende productiemethodologie, welke Grid Manufacturing is genoemd. Grid Manufacturing wordt uitgevoerd door autonome entiteiten (agenten) die zowel de productiesystemen zelf, als de producten representeren. Producten leven dan al in de virtuele cyber wereld voordat zij daadwerkelijk zijn gebouwd, en zijn zich bewust uit welke onderdelen zij gemaakt moeten worden. De producten communiceren en overleggen met de autonome herconfigureerbare productiesystemen, de zogenaamde equiplets. Deze equiplets leveren generieke diensten aan een grote diversiteit aan producten, die hierdoor op elk moment geproduceerd kunnen worden. Het onderzoek focust hierbij specifiek op de equiplets en de technische uitdagingen om dynamisch geautomatiseerde productie mogelijk te maken. Om Grid Manufacturing mogelijk te maken is er een set van technologische uitdagingen onderzocht. De achtergrond, onderzoeksaanpak en concepten zijn dan ook de eerste drie inleidende hoofdstukken. Daarna begint het onderzoek met Hoofdstuk 4 Object Awareness. Dit hoofdstuk beschrijft een dynamische manier waarop informatie uit verschillende autonome systemen gecombineerd wordt om objecten te herkennen, lokaliseren en daarmee te kunnen manipuleren. Hoofdstuk 5 Herconfiguratie beschrijft hoe producten communiceren met de equiplets en welke achterliggende systemen ervoor zorgen dat, ondanks | Dutch Summary 232 dat het product niet bekend is met de hardware van de equiplet, deze toch in staat is acties uit te voeren. Tevens beschrijft het hoofdstuk hoe de equiplets omgaan met verschillende hardwareconfiguraties en ondanks de aanpassingen zichzelf toch kunnen besturen. De equiplet kan dan ook aangepast worden zonder dat deze opnieuw geprogrammeerd hoeft te worden. In Hoofdstuk 6 Architectuur wordt vervolgens dieper ingegaan op de bovenliggende architectuur van de equiplets. Hier worden prestaties gecombineerd met flexibiliteit, waarvoor een hybride architectuur is ontwikkeld die het grid van equiplets controleert door het gebruik van twee platformen: Multi-Agent System (MAS) en Robot Operating System (ROS). Nadat de architectuur is vastgesteld, wordt er in Hoofdstuk 7 onderzocht hoe deze veilig ingezet kan worden. Hierbij wordt een controlesysteem ingevoerd dat het systeemgedrag bepaalt, waarmee het gedrag van de equiplets transparant wordt gemaakt. Tevens zal een simulatie met input van de sensoren uit de fysieke wereld ’live’ controleren of alle bewegingen veilig uitgevoerd kunnen worden. Nadat de basisfunctionaliteit van het Grid nu compleet is, wordt in Hoofdstuk 8 Validatie en Utilisatie gekeken naar hoe Grid Manufacturing gebruikt kan worden en welke nieuwe mogelijkheden deze kan opleveren. Zo wordt er besproken hoe zowel een hi¨erarchische als een heterarchische aanpak, waar alle systemen gelijk zijn, gebruikt kan worden. Daarnaast laat het hoofdstuk o.a. aan de hand van enkele voorbeelden en simulaties zien welke effecten herconfiguratie kan hebben, en welke voordelen deze aanpak zoal kan bieden.. Het proefschrift laat zien hoe met technische middelen geautomatiseerde flexibiliteit mogelijk wordt gemaakt. Hoewel het gehele concept nog volwassen zal moeten worden, worden er enkele aspecten getoond die op de korte termijn toepasbaar zijn in de industrie. Enkele voorbeelden hiervan zijn: (1) het combineren van gegevens uit diverse (autonome) bronnen voor 6D-lokalisatie; (2) een data-gedreven systeem, de zogeheten hardware-abstractielaag, die herconfigureerbare systemen controleert en de mogelijkheid biedt om deze productiesystemen aan te passen zonder deze te hoeven herprogrammeren; en (3) het gebruik van Cyber-Fysieke systemen om de veiligheid te verhogen.
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Standard mass-production is a well-known manufacturing concept. To make small quantities or even single items of a product according to user specifications at an affordable price, alternative agile production paradigms should be investigated and developed. The system presented in this paper is based on a grid of cheap reconfigurable production units, called equiplets. A grid of these equiplets is capable to produce a variety of different products in parallel at an affordable price. The underlying agent-based software for this system is responsible for the agile manufacturing. An important aspect of this type of manufacturing is the transport of the products along the available equiplets. This transport of the products from equiplet to equiplet is quite different from standard production. Every product can have its own unique path along the equiplets. In this paper several topologies are discussed and investigated. Also, the planning and scheduling in relation to the transport constraints is subject of this study. Some possibilities of realization are discussed and simulations are used to generate results with the focus on efficiency and usability for different topologies and layouts of the grid and its internal transport system.
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When using autonomous reconfigurable manufacturing system, that offers generic services, there is the possibility to dynamically manufacture a range of products using the same manufacturing equipment. Opportunities are created to optimally scale the production using reconfiguration means and automatically manufacture small amounts of unique or highly customizable products. Basically the result is a short time to market for new products. This paper discusses the problems that arise when manufacturing systems are reconfigured and the impact of this action on the entire system. The proposed software architecture and tooling makes it possible to quickly reconfigure a system without interference to other system, and shows how the reconfigured hardware can be controlled without the need to reprogram the software. Parameters that are required to control the new hardware can be added using a simple tool. As a result reconfiguration is simplified and can be achieved quickly by mechanics without reprogramming any systems. The impact is that time to market can be reduced and manufacturing systems can quickly be adapted to current real-time needs.
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Standard mass-production is a well-known manufacturing concept. To make small quantities or even single items of a product according to user specifications at an affordable price, alternative agile production paradigms should be investigated and developed. The system presented in this article is based on a grid of cheap reconfigurable production units, called equiplets. A grid of these equiplets is capable to produce a variety of different products in parallel at an affordable price. The underlying agent-based software for this system is responsible for the agile manufacturing. An important aspect of this type of manufacturing is the transport of the products along the available equiplets. This transport of the products from equiplet to equiplet is quite different from standard production. Every product can have its own unique path along the equiplets. In this article several topologies are discussed and investigated. Also, the planning and scheduling in relation to the transport constraints is subject of this study. Some possibilities of realization are discussed and simulations are used to generate results with the focus on efficiency and usability for different topologies and layouts of the grid and its internal transport system. Closely related with this problem is the scheduling of the production in the grid. A discussion about the maximum achievable load on the production grid and its relation with the transport system is also included.
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Sustainable and Agile manufacturing is expected of future generation manufacturing systems. The goal is to create scalable, reconfigurable and adaptable manufacturing systems which are able to produce a range of products without new investments into new manufacturing equipment. This requires a new approach with a combination of high performance software and intelligent systems. Other case studies have used hybrid and intelligent systems in software before. However, they were mainly used to improve the logistic processes and are not commonly used within the hardware control loop. This paper introduces a case study on flexible and hybrid software architecture, which uses prototype manufacturing machines called equiplets. These systems should be applicable for the industry and are able to dynamically adapt to changes in the product as well as changes in the manufacturing systems. This is done by creating self-configurable machines which use intelligent control software, based on agent technology and computer vision. The requirements and resulting technologies are discussed using simple reasoning and analysis, leading to a basic design of a software control system, which is based on a hybrid distributed control system
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Abstract: Unlike manufacturing technology for semiconductors and printed circuit boards, the market for traditional micro assembly lacks a clear public roadmap. More agile manufacturing strategies are needed in an environment in which dealing with change becomes a rule instead of an exception. In this paper, an attempt is made to bring production with universal micro assembly cells to the next level. This is realised by placing a larger number of cells, called Equiplets, in a “Grid”. Equiplets are compact and low-cost manufacturing platforms that can be reconfigured to a broad number of applications. Benchmarking Equiplet production has shown reduced time to market and a smooth transition from R&D to Manufacturing. When higher production volumes are needed, more systems can be placed in parallel to meet the manufacturing demand. Costs of product design changes in the later stage of industrialisation have been reduced due to the modular production in grids, which allows the final design freeze to be postponed as late as possible. The need for invested capital is also pushed backwards accordingly. doi 10.1007/978-3-642-11598-1_32
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