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Online Hazard Detection in Reconfigurable Plug & Produce Systems
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)ORCID iD: 0000-0002-6604-6904
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)ORCID iD: 0000-0002-4091-7732
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)
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2024 (English)In: Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems.: FAIM 2023 / [ed] Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G., Springer Nature, 2024, p. 889-897Conference paper, Oral presentation with published abstract (Refereed)
Abstract [en]

Plug & Produce is a modern automation concept in smart manufacturing for modular, quick, and easy reconfigurable production. The system’s flexibility allows for the configuration of production with abstraction, meaning that the production resources participating in a specific production plan are only known in the online phase. The safety assurance process of such a system is complex and challenging. This work aims to assist the safety assurance when utilizing a highly flexible Plug & Produce concept that accepts instant logical and physical reconfiguration. In this work, we propose a concept for online hazard identification of Plug & Produce systems, the proposed concept, allows for the detection of hazards in the online phase and assists the safety assurance as it provides the hazard list of all possible executable alternatives of the abstract goals automatically. Further, it combines the safety-related information with the control logic allowing for safe planning of operations. The concept was validated with a manufacturing scenario that demonstrates the effectiveness of the proposed concept.

Place, publisher, year, edition, pages
Springer Nature, 2024. p. 889-897
Series
Lecture Notes in Mechanical Engineering
Keywords [en]
Plug & Produce, reconfigurable manufacturing, safety assessment, hazard identification
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-20884DOI: 10.1007/978-3-031-38241-3_97Scopus ID: 2-s2.0-85171556008ISBN: 9783031382406 (print)ISBN: 9783031382413 (electronic)OAI: oai:DiVA.org:hv-20884DiVA, id: diva2:1822875
Conference
International Conference on Flexible Automation and Intelligent Manufacturing FAIM 2023, 18-22 June, Porto, Portugal
Available from: 2023-12-28 Created: 2023-12-28 Last updated: 2024-01-30
In thesis
1. Planning and Control of Safety-Aware Plug & Produce
Open this publication in new window or tab >>Planning and Control of Safety-Aware Plug & Produce
2024 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The Plug & Produce manufacturing system is a visionary concept that promises to facilitate the seamless integration and adaptation of manufacturing resources and production processes. The Plug & Produce control system allows for the automatic addition and removal of manufacturing resources, minimizing human intervention. However, the reconfigurability and autonomous decision-making features of Plug & Produce control systems pose challenges to safety design and control functions.

In contrast to conventional manufacturing systems with fixed layouts and processes, ensuring safety in Plug & Produce systems is complicated due to the complex risk assessment process, the difficulty of implementing non-restrictive safety measures covering all possible hazards, and the challenge of designing a reliable controller for consistent safe operation.

This thesis addresses these challenges through various contributions. It introduces an automatic hazard identification method, considering emergent hazards after reconfiguration. A novel domain ontology is developed, incorporating safety models specific to Plug & Produce systems. The work also proposes a generic, model-based, and automatic risk assessment method, along with a method for the safe execution of plans based on the results of the risk assessment.

The results of this research offer benefits to process planners, who are responsible for coordinating the manufacturing processes with product design in the Plug & Produce system. The proposed solution provides tools for process planners to validate their plans and reduces their safety-related responsibilities. The proposed safety assurance method seamlessly integrates into the multi-agent control of Plug & Produce, providing the control system with risk scenarios associated with process plans. This enables proactive and reliable control, effectively avoiding potential risks during system operation.

Abstract [sv]

Föreställ dig en automatiserad produktionsanläggning som omedelbart och automatiskt kan anpassa sig till förändringar utan att kompromissa med säkerheten för den personal som arbetar där. Denna avhandling strävar efter att uppnå just detta genom ett smartare sätt att säkerställa att produktionsanläggningar baserat på Plug & Produce kan hantera säkerhet. Dettainnebär att konceptet Plug & Produce nu närmar sig ett industriellt förverkligande. Säkerhet för automatiserade produktionsanläggningar innebär att alla maskiner ska vara utrustade med skydd för att göra arbetet säkrare. Idag är det vanligt med övervakning som skydd, dvs en dator som övervakar att allt går rätt till och stänger av om något är på väg att hända. I ett produktionsavsnitt som är baserat på Plug & Produce kan man enkelt ställa om, det vill säga, lägga till eller ta bort maskiner, ändra layouten eller ändra på produkter som produceras. Efter en sådan omställning så måste säkerheten i produktionsanläggningen ses över enligt föreskrivna lagar och regler. Traditionellt så kräver detta anlitande av en säkerhetsexpert. Detta medför att en omställning utifrån ett säkerhetsperspektiv är både kostsamt och tidskrävande. Med resultatet från denna avhandling så går det nu att ställa om utan att behöva implementera nya säkerhetsfunktioner efter varje förändring. Denna forskning har utvidgat kunskapsområdet inom produktionsteknik för att skapa en "smartarefabrik" genom att inkludera säkerhetsfunktioner.Resultatet inkluderar algoritmer som kan upptäcka potentiella faror i fabriken och automatiskt tillämpa säkerhetsåtgärder för ett övervakat system. Detta innebär mindre tidsåtgång och lägre kostnader för säkerhetsarbetet. De som drar mest nytta av detta är människorna som planerar för hur saker skall tillverkas med hjälp av Plug & Produce. Resultatet av detta arbete underlättar deras arbetsuppgifter och bevarar flexibiliteten i Plug & Produce, vilket eliminerar behovet av att välja mellan flexibilitet och säkerhet

Place, publisher, year, edition, pages
Trollhättan: University West, 2024. p. 54
Series
Licentiate Thesis: University West ; 45
Keywords
Plug & Produce, safety assurance, process planning, reconfigurable manufacturing
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-21142 (URN)9789189325661 (ISBN)9789189325654 (ISBN)
Presentation
2024-03-08, 111, Gustava Melins gata, Trollhättan, 09:00 (English)
Opponent
Supervisors
Available from: 2024-03-08 Created: 2024-01-30 Last updated: 2024-03-15

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Massouh, BassamDanielsson, FredrikRamasamy, SudhaKhabbazi, Mahmood RezaZhang, Xiaoxiao

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