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A Virtual Real-Time Model for Control Software Development: applied on a Sheet-Metal Press Line
University West, Department of Engineering Science, Division of Electrical and Automation Engineering.ORCID iD: 0000-0002-8878-2718
University West, Department of Engineering Science, Division of Electrical and Automation Engineering.ORCID iD: 0000-0002-6604-6904
University West, Department of Engineering Science, Division of Electrical and Automation Engineering.
2005 (English)In: Industrial Simulation Conference 2005 / [ed] Jörg Kruger, Alexei Lisounkin, Gerhard Schreck, 2005, 119-123 p.Conference paper, Published paper (Refereed)
Place, publisher, year, edition, pages
2005. 119-123 p.
Keyword [en]
virtual manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-2296ISBN: 90-77381-18-X (print)OAI: oai:DiVA.org:hv-2296DiVA: diva2:304209
Conference
3rd International Industrial Simulation Conference, ISC'2005, June 9-11, Fraunhofer IPK, Berlin, Germany
Available from: 2010-03-17 Created: 2010-03-17 Last updated: 2014-05-08Bibliographically approved
In thesis
1. Optimisation of Manufacturing Systems Using Time Synchronised Simulation
Open this publication in new window or tab >>Optimisation of Manufacturing Systems Using Time Synchronised Simulation
2010 (English)Licentiate thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Göteborg: Chalmers, 2010. 42 p.
Series
Technical Report R Department of Signals and Systems, Chalmers University of Technology, ISSN 1403-266X ; 2010:003
Keyword
Simulation based optimisation, virtual manufacturing, industrial control system, PLC, continuous simulation, parameter tuning, optimisation methods
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2481 (URN)
Presentation
(English)
Available from: 2010-05-25 Created: 2010-05-21 Last updated: 2016-02-09Bibliographically approved
2. A Simulation-Based Optimisation Method for PLC Systems
Open this publication in new window or tab >>A Simulation-Based Optimisation Method for PLC Systems
2012 (English)Doctoral thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Göteborg: Chalmers, 2012. 65 p.
Series
Doktorsavhandlingar vid Chalmers tekniska högskola Ny serie, ISSN 0346-718X ; 3340
Keyword
Simulation based optimisation, Virtual manufacturing, Industrial control system, PLC, Continuous simulation, Parameter tuning, Optimisation methods
National Category
Robotics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-4646 (URN)978-91-7385-659-1 (ISBN)
Public defence
2012-04-13, Lecture room C118, University West, Gustava Melins gata 2, Trollhättan, 10:15 (English)
Opponent
Supervisors
Available from: 2012-09-25 Created: 2012-09-19 Last updated: 2016-02-09Bibliographically approved

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