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Reliable Virtual Commissioning
University West, Department of Engineering Science, Division of Automation and Computer Engineering. (PTW)
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. , 54 p.
Series
Technical Report No R012/2012, ISSN 403-266X
Keyword [en]
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: urn:nbn:se:hv:diva-4701OAI: oai:DiVA.org:hv-4701DiVA: diva2:558120
Presentation
2012-09-21, Trollhättan, 10:00 (English)
Supervisors
Available from: 2012-10-12 Created: 2012-10-01 Last updated: 2015-10-02Bibliographically approved
List of papers
1. Methods for Reliable Simulation-Based PLC Code Verification
Open this publication in new window or tab >>Methods for Reliable Simulation-Based PLC Code Verification
2012 (English)In: IEEE Transactions on Industrial Informatics, ISSN 1551-3203, E-ISSN 1941-0050, ISSN 1551-3203, Vol. 8, no 2, 267-278 p.Article 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
National Category
Robotics
Research subject
ENGINEERING, Mechatronics
Identifiers
urn:nbn:se:hv:diva-3154 (URN)10.1109/TII.2011.2182653 (DOI)000302720000007 ()2-s2.0-84859894562 (Scopus ID)
Available from: 2011-01-28 Created: 2011-01-28 Last updated: 2016-02-08Bibliographically approved
2. 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
3. Automated Generation of Discrete Event System Simulation Models for Flexible Automation
Open this publication in new window or tab >>Automated Generation of Discrete Event System Simulation Models for Flexible Automation
2011 (English)In: The 21st International Conference on Flexible Automation and Intelligent Manufacturing: Taichung, Taiwan, June 26-29 2011, 2011, 825-832 p.Conference paper, (Refereed)
Abstract [en]

Flexible automation cells with rapid product changes are an important competitive advantage for industries today. These cells can increase a company’s productivity and thereby increase their profits. A flexible cell shall be able to handle different products with none or minimal changes to the cell itself. A powerful tool, which can be used to analyse and verify such cells, is discrete event system simulation. Problems such as potential bottlenecks, deadlocks, answers to "what-if" questions and the level of resource utilisation can be gathered. The drawback of discrete event system simulation is that the modelling task is both time consuming and difficult to accomplish. Furthermore, state-of-the-art discrete event system simulation tools that are used in the industry today are not suitable for flexible automation. If the production scenario is changed, e.g. introduction of a new product, the simulation and modelling has to be redone and this is both time consuming and tedious. In this paper a new approach will be presented that enables discrete event simulation models to be generated automatically. The models are generated from information retrieved from a PLM/PDM database system, which is shared among other engineering tools such as robot simulation, CAD and process planning. Hence, when the cell and the database are updated a new model can easily be generated. The database is also connected to the real cell so up-to-date data can be retrieved from the real cell. The model generator described in this paper was implemented and tested in a discrete event system simulation tool and showed promising results. With this approach it is possible to handle flexible automation cells more effectively in a process planning stage.

Keyword
Flexible Automation
National Category
Robotics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-3779 (URN)978-986-87291-0-0 (ISBN)
Conference
FAIM 2011
Note
Konferense publicerad på USB-minneAvailable from: 2011-10-13 Created: 2011-10-13 Last updated: 2014-05-08Bibliographically approved

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