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Off-Line Optimisation of Complex Automated Production Lines: Applied on a Sheet-Metal Press Line
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik.ORCID-id: 0000-0002-8878-2718
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik.ORCID-id: 0000-0002-6604-6904
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik.
2007 (Engelska)Ingår i: Proceedings of the 2007 IEEE International Symposium on Assembly and Manufacturing, IEEE , 2007, s. 82-87Konferensbidrag, Publicerat paper (Refereegranskat)
Abstract [en]

This paper presents a successful off-line

optimisation case study of a sheet-metal press line for the

automotive industry. The proposed off-line optimisation

method results not only in increased production rate but also in

obtaining smoother material handling motions. The off-line

optimisation method contains two parts. The first part is a

parameter study, combining factorial design with production

line simulation including emulated control systems and

resulting in a simplified performance model based on multiple

linear regression. The second part is an optimisation on the

simplified performance model using the Nelder Mead simplex

method aiming at production optimisation. Due to the

complexity in a modern production line, it is not possible to

create a useful model representation of the entire control

system code/function. Therefore, the proposed optimisation

method is based on using production line simulation including

emulated control systems with the real IEC 61131-3 control

code. Our approach in this work is a parameter variation

strategy for optimisation, i.e. adjusting the control system

parameters in the same way as the line operators do, and not

changing any control strategy.

Ort, förlag, år, upplaga, sidor
IEEE , 2007. s. 82-87
Nyckelord [en]
virtual manufacturing
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi
Forskningsämne
TEKNIK, Produktions- och materialteknik
Identifikatorer
URN: urn:nbn:se:hv:diva-210DOI: 10.1109/ISAM.2007.4288453ISBN: 1-4244-0563-7 (tryckt)OAI: oai:DiVA.org:hv-210DiVA, id: diva2:212714
Konferens
IEEE International Symposium on Assembly and Manufacturing, ISAM 2007,Ann Arbor, Michigan, USA, July 22-25, 2007
Tillgänglig från: 2009-04-23 Skapad: 2009-04-23 Senast uppdaterad: 2014-05-08Bibliografiskt granskad
Ingår i avhandling
1. Optimisation of Manufacturing Systems Using Time Synchronised Simulation
Öppna denna publikation i ny flik eller fönster >>Optimisation of Manufacturing Systems Using Time Synchronised Simulation
2010 (Engelska)Licentiatavhandling, sammanläggning (Övrigt vetenskapligt)
Ort, förlag, år, upplaga, sidor
Göteborg: Chalmers, 2010. s. 42
Serie
Technical Report R Department of Signals and Systems, Chalmers University of Technology, ISSN 1403-266X ; 2010:003
Nyckelord
Simulation based optimisation, virtual manufacturing, industrial control system, PLC, continuous simulation, parameter tuning, optimisation methods
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi
Forskningsämne
TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-2481 (URN)
Presentation
(Engelska)
Tillgänglig från: 2010-05-25 Skapad: 2010-05-21 Senast uppdaterad: 2016-02-09Bibliografiskt granskad
2. A Simulation-Based Optimisation Method for PLC Systems
Öppna denna publikation i ny flik eller fönster >>A Simulation-Based Optimisation Method for PLC Systems
2012 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

Tuning of process parameters such as time constants, cam values, velocities and robot paths, in order to increase capacity utilisation, is today a challenging manual on-line task in many automated manufacturing systems. On-line methods interfere with production and will cause unwanted downtime, which indeed reduces capacity utilisation. The literature offers virtual manufacturing and simulation-based optimisation as an approach, but without handling time-synchronised control functions, e.g. motion and feedback control.

This thesis presents a simulation-based optimisation method for PLC systems, able to handle time-synchronised control functions. A programmable logic controller (PLC) is a commonly used type of industrial control system that is capable of handling all control functions in a manufacturing system. The approach presented in this thesis is, however, independent of the type of control systems used. Hence, PLC is used as a general name for all control systems, managing all discrete event, continuous feedback, motion, supervisory, as well as safety control functions.

A generic simulation-based method for tuning of process parameters has been formulated.  Various goals are attainable by a multi-criteria optimisation approach. The idea is to use a time-synchronised hardware-in-the-loop simulation including real PLCs. By this approach, the method provides a distinct advantage as it involves all complex control functions by using the real PLC code. An additional benefit is that all tuned process parameters can be directly transferred to the PLCs in the manufacturing plant.

To achieve a feasible simulation-based optimisation method for PLC systems, a new Combined Lipschitzian and Simplex (CoLiS) optimisation algorithm has been established. Complex control functions in industrial manufacturing systems cause conditions such as highly non-linear functions with multiple local optima, a considerable number of parameters and long evaluation times. All these conditions are managed by the non-gradient global CoLiS algorithm. The CoLiS algorithm starts with a global search and then switches over to local convergence. Additionally, all local optima determined during the global search are selected and then constitute starting points in separate local optimisation instances.

To verify the formulated method’s suitability in industrial applications, and the effectiveness of the new CoLiS algorithm, an optimisation case study has been performed. Improved production performance, both in terms of increased production rate and smoother robot motions, was reached in an automotive sheet-metal press line.

Ort, förlag, år, upplaga, sidor
Göteborg: Chalmers, 2012. s. 65
Serie
Doktorsavhandlingar vid Chalmers tekniska högskola Ny serie, ISSN 0346-718X ; 3340
Nyckelord
Simulation based optimisation, Virtual manufacturing, Industrial control system, PLC, Continuous simulation, Parameter tuning, Optimisation methods
Nationell ämneskategori
Robotteknik och automation
Forskningsämne
TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-4646 (URN)978-91-7385-659-1 (ISBN)
Disputation
2012-04-13, Lecture room C118, University West, Gustava Melins gata 2, Trollhättan, 10:15 (Engelska)
Opponent
Handledare
Tillgänglig från: 2012-09-25 Skapad: 2012-09-19 Senast uppdaterad: 2016-02-09Bibliografiskt granskad

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