Change search
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
Methods for Reliable Simulation-Based PLC Code Verification
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (Virtual Manufacturing, PTW)
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0002-8878-2718
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0002-6604-6904
Chalmers University of Technology, Department of Signals and Systems.
2012 (English)In: IEEE Transactions on Industrial Informatics, ISSN 1551-3203, E-ISSN 1941-0050, ISSN 1551-3203, Vol. 8, no 2, p. 267-278Article in journal (Refereed) Published
Abstract [en]

Simulation based PLC code verification is a part of virtual commissioning, where the control code is verified against a virtual prototype of an application. With today’s general OPC interface it is easy to connect a PLC to a simulation tool for e.g. verification purposes. However, there are some problems with this approach that can lead to an unreliable verification result. In this paper, four major problems with the OPC interface are described, and two possible solutions to the problems are presented: a general IEC 61131-3 based software solution, and a new OPC standard solution

Place, publisher, year, edition, pages
Piscataway, NJ: IEEE-inst electrical electronics engineers , 2012. Vol. 8, no 2, p. 267-278
National Category
Robotics
Research subject
ENGINEERING, Mechatronics
Identifiers
URN: urn:nbn:se:hv:diva-3154DOI: 10.1109/TII.2011.2182653ISI: 000302720000007Scopus ID: 2-s2.0-84859894562OAI: oai:DiVA.org:hv-3154DiVA, id: diva2:392951
Available from: 2011-01-28 Created: 2011-01-28 Last updated: 2017-12-11Bibliographically approved
In thesis
1. 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. p. 65
Series
Doktorsavhandlingar vid Chalmers tekniska högskola Ny serie, ISSN 0346-718X ; 3340
Keywords
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
2. Reliable Virtual Commissioning
Open this publication in new window or tab >>Reliable Virtual Commissioning
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Virtual commissioning is a technique for programming, optimising and verifying industrial automated production, such as robot controllers and programmable logic controllers (PLC), off-line in a simulated environment. Compared with traditional robot off-line programming and simulation, the scope is wider and can include an entire production cell.

Robot simulation is a well-established technique and widely used in industry today, much thanks to the RRS interface that enables simulated robot control systems to be integrated in the simulation software. A more general interface for industrial control system integration is OPC that has been an industrial de facto standard for connection between industrial control systems and regular PCs. State-of-the-art production simulation tools often include the possibility to connect an industrial control system via OPC. However, OPC suffers a major drawback when it comes to production simulation, there is no mechanism that synchronises the industrial control system with the simulation and this could lead to unreliable results from the simulation.

Another obstacle for virtual commissioning is the amount of time that needs to be spent during the simulation model building phase, since virtual commissioning includes more signals. This does not only take more time, but it is also an error prone process that might lead to unreliable results.

In this thesis problems related to the OPC interface and the modelling process are discussed, and suggestions how these issues can be solved are presented so reliable virtual commissioning can be achieved.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2012. p. 54
Series
Technical Report No R012/2012, ISSN 1403-266X
Keywords
Virtual commissioning, Simulation based PLC control code verification, Virtual manufacturing, Industrial control system, PLC, Continuous simulation
National Category
Robotics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-4701 (URN)
Presentation
2012-09-21, Trollhättan, 10:00 (English)
Supervisors
Available from: 2012-10-12 Created: 2012-10-01 Last updated: 2018-03-20Bibliographically approved

Open Access in DiVA

No full text in DiVA

Other links

Publisher's full textScopushttp://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=6121945

Authority records BETA

Svensson, BoDanielsson, Fredrik

Search in DiVA

By author/editor
Carlsson, HenrikSvensson, BoDanielsson, Fredrik
By organisation
Division of Electrical and Automation Engineering
In the same journal
IEEE Transactions on Industrial Informatics
Robotics

Search outside of DiVA

GoogleGoogle Scholar

doi
urn-nbn

Altmetric score

doi
urn-nbn
Total: 1580 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf