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Optimisation of Manufacturing Systems Using Time Synchronised Simulation
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0002-8878-2718
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 [en]
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: urn:nbn:se:hv:diva-2481OAI: oai:DiVA.org:hv-2481DiVA: diva2:320118
Presentation
(English)
Available from: 2010-05-25 Created: 2010-05-21 Last updated: 2016-02-09Bibliographically approved
List of papers
1. A General Virtual Manufacturing Concept for Programming, Verification and Optimisation of Complex Control Functions
Open this publication in new window or tab >>A General Virtual Manufacturing Concept for Programming, Verification and Optimisation of Complex Control Functions
2008 (English)In: Proceedings of the 18th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2008: June 30th - July 2nd, 2008, University of Skövde, Sweden / [ed] Leo J. de Vin, Skövde, 2008, 668-675 p.Conference paper, (Refereed)
Abstract [en]

This paper describes a general virtual manufacturing concept for industrial control systems. Our virtual manufacturing concept provides a distinct advantage; programming, verification and optimisation of complex real-time dependent control functions described by real control code, which can be directly transferred to the real manufacturing system. To achieve this distinct advantage, a time synchronised virtual manufacturing system is a necessity. The aim of this paper is thus to present and to describe in detail, our proposed virtual manufacturing concept. To the authors’ knowledge no such general virtual manufacturing concept, i.e. one that can correctly handle complex real-time dependent control functions, currently exists. To summarise previous work related to virtual manufacturing and industrial control systems, several critical issues have been identified. The virtual manufacturing concept proposed in this paper addresses these issues. To verify that our concept can manage these critical issues found and further is suitable in industrial applications a virtual manufacturing test case is also presented. The test case, that includes motion control (i.e. servo), complex control functions, real control systems etc., was carried out with success.

Place, publisher, year, edition, pages
Skövde: , 2008
National Category
Control Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2068 (URN)978-91-633-2757-5 (ISBN)
Conference
18th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2008), Skövde, 30 june-2 july 2008
Available from: 2009-12-18 Created: 2009-12-18 Last updated: 2016-02-09Bibliographically approved
2. Off-Line Optimisation of Complex Automated Production Lines: Applied on a Sheet-Metal Press Line
Open this publication in new window or tab >>Off-Line Optimisation of Complex Automated Production Lines: Applied on a Sheet-Metal Press Line
2007 (English)In: Proceedings of the 2007 IEEE International Symposium on Assembly and Manufacturing, IEEE , 2007, 82-87 p.Conference paper, (Refereed)
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.

Place, publisher, year, edition, pages
IEEE, 2007
Keyword
virtual manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-210 (URN)10.1109/ISAM.2007.4288453 (DOI)1-4244-0563-7 (ISBN)
Conference
IEEE International Symposium on Assembly and Manufacturing, ISAM 2007,Ann Arbor, Michigan, USA, July 22-25, 2007
Available from: 2009-04-23 Created: 2009-04-23 Last updated: 2014-05-08Bibliographically approved
3. A Virtual Real-Time Model for Control Software Development: applied on a Sheet-Metal Press Line
Open this publication in new window or tab >>A Virtual Real-Time Model for Control Software Development: applied on a Sheet-Metal Press Line
2005 (English)In: Industrial Simulation Conference 2005 / [ed] Jörg Kruger, Alexei Lisounkin, Gerhard Schreck, 2005, 119-123 p.Conference paper, (Refereed)
Keyword
virtual manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2296 (URN)90-77381-18-X (ISBN)
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
4. Simulation based optimization of a sheet-metal press line
Open this publication in new window or tab >>Simulation based optimization of a sheet-metal press line
2009 (English)In: IEEE Conference on Emerging Technologies & Factory Automation, ETFA 2009, 2009, 1-8 p.Conference paper, (Refereed)
Abstract [en]

An off-line optimization of a sheet-metal press line is performed with improved production performances, both in terms of increased production rate and smoother robot motions. Smooth motions prevent the sheet-metal to slide out of position or even fall out, thereby causing lengthy down times. The simulation based method use a process optimizer connected to a time synchronized virtual manufacturing model including real industrial control systems, e.g. PLC. The key benefit herein is that all tuned control system parameters can be directly downloaded to the real press line without any post-processing or transformations. The challenge to find suitable optimization algorithms for a press line that handle highly nonlinear, discontinuous functions; considerable number of parameters; and long evaluation times is reached.

Series
IEEE Conference Publications, ISSN 1946-0759
Keyword
industrial robots, nonlinear functions, optimisation, sheet metal processing, PLC, discontinuous function, industrial control systems, nonlinear function, off-line optimization, production rate, robot motions, sheet-metal press line, simulation-based optimization, smooth motions, time synchronized virtual manufacturing model
National Category
Control Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2214 (URN)10.1109/ETFA.2009.5346992 (DOI)978-1-4244-2727-7 (ISBN)978-1-4244-2728-4 (ISBN)
Conference
IEEE Conference on Emerging Technologies & Factory Automation, ETFA 2009, Sep 22-25, Palma de Mallorca, Spain
Available from: 2010-02-15 Created: 2010-02-15 Last updated: 2016-02-09Bibliographically approved

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