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An Overview of RapidCIM Concepts
Richard A. WyskIE551 - Computer Control of Manufacturing
Systems
R ap idC IMP ro jec t
R ap idC IM
P S U
T A M U
S y stemD e sig n e r
S y ste mO p era to rs
A C M Ep rod u ces gene ra tes
c o n tro ls
O w n e r
X
co n tro ls
co n tro ls
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Agenda• Traditional Software Development• Motivation for RapidCIM• RapidCIM Concepts• Equipment Level Models• Message-based Part State Graphs• Conclusions• Resources
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IntroductionAutomated
Flexible Manufacturing Cells/Shops
HardwareSystemControl
Software
ProgrammingTools &
Software
Tools to assist indevelopment ofSystem Control
Software
Input Input ????
????NC ProgrammingOffline Robot Programmingetc.
CAD Modelsetc.
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Traditional Control Software Development
In traditional “PLC-type” control, the control software is developed using the same planning, scheduling, and execution flow diagram.
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Traditional Control Software Development
Planning (determining part routes) and scheduling (sequencing tasks) are built into the control software - Similar to a PLC ladder diagram.
Adding new parts or changing the scheduling rules require significant modifications to the control software
These changes must be done by the FMS vendor instead of the system operators
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Motivation For RapidCIM Most current FMS control implementations
are customized Lack of generic tools
Limitations in flexibility and reconfiguration High cost of reliable software development
2/3 rd of total expenditure is incurred during implementation phase, due to errors in software design
approx. 64% of the errors are made at the concept stage and only 36% are programming errors
On average, 50% or more of the software costs for flexible automation are related to control
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Shop-floor control Lack of emphasis on software
development Architectures do not provide sufficient detail Software requirements have not been
systematically analyzed to separate generic requirements from implementation-specific requirements
Functions performed are too tightly coupled Tools to aid in the manufacturing
system software development do not exist
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RapidCIM Project
R ap id C IMP ro jec t
R apidC IM
P S U
T A M U
S y stemD e sig n e r
S y ste mO p era to rs
A C M Ep rod u c es ge nera tes
c o n tro ls
O w n e r
X
c o n tro ls
c o n tro ls
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Specific Tasks Understand the control elements of a FMS Develop theoretical foundations for FMS
control, through use of formal models Create generic model of control
independent of implementation specifics Automatic generation of control software
for various controllers in the cell using the formal models
Create a FMS control software development methodology which can be implemented as a set of domain specific CASE tools
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Control Software Need Software
That is generic and hence reuseable
Easily customized per installation
Modular & modules being “plug compatible”
Shop Floor Control Software
Generic Implementation Specific
AutomaticallyGenerated
HandCoded
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Hierarchical ArchitectureS ho p
E q u ipE q u ip
W k s tn
E q u ipE q u ip
W ks tn
E q u ipE q u ip
R e s o u rc eM a na g e r
W ks t n
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Control Hierarchy EQUIPMENT
Physical devices (NC machines, robots, AGV, ASRS, programmable fixtures, buffers, etc)
WORKSTATION Integrated pieces of equipment Robot tending a single machining center, along
with requisite fixtures, sensors, etc. Robot tending several machines
SHOP Several integrated workstations, coupled by
material transport workstations
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Equipment Level Each controllable equipment is
viewed as comprising Physical device controller (supplied with
machine) Equipment controller (typically a PC)
Generic Classes of Equipment MP - Material Processor (NC machine, CMM) MH - Material Handler (robot) MT - Material Transporter (AGV, conveyor) AS - Automated Storage Device
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EQUIPMENT LEVEL (Cont) Non Controllable equipment
BS - passive buffer storage devices PD - passive devices
Ports (entry and exit of parts) PO - ports
Equipment level controller incorporates a device driver, that implements
the equipment level functions (cycle start, download, etc)
This is the implementation specific portion
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Workstation Level Workstation comprises
equipment (MP, MH, PO, BS, MT ....) Types of Workstation
Processing workstation Transport Workstation Storage Workstation
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Planning, Scheduling, and Execution Planning
Determining what tasks thesystem needs to perform
SchedulingSequencing planned tasks
ExecutionPerforming the scheduledtasks at the appropriatetime
S ystem O p era tio n
P lann in g
S ch ed u lin g
E x ecu tio n
P h ysica lS ys tem
P la nn ed ta sk s
S ch ed u led ta sk s
T ask s
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Functional ArchitectureLEVEL
FUNCTIONS
EQUIPMENT WORKSTATION SHOP
PLANNINGTool Selection, Toolpath refinement
Tool assignment toslots, job set upplanning
Resource allocations
Batch splitting
Equipment LoadBalancing
Batching
Worlokad Balancingbetween workstations
Task allocation toworkstations
SCHEDULING Operation sequencingat individualequipment
-Sequence equipment levelsubsystems
-Deadlock Detection
Buffer Management
Assignment of due dates toworkstations
Batch sequencing andmanagement
EXECUTION Interface toworkstation controller
Physical control ofmachinesExecution of control
Monitor equipment statesand execute part andinformation flow based onstates
Synchronization
Organizational control ofworkstaions
Interface with MRP
Report Generation
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Shop Floor Controller Structure
ProductionR equirem ents
C ontro lle r
PhysicalSystem
I/O C h anne ls
P lanner S cheduler Ex ecuto r
TaskList
I/O C hann el
Syste m M o del
PhysicalM odel
SystemSta tus
PhysicalConfigura tion
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Part Flow Through the Shop
E nte rS hop
D elive r toW ks tn
P ut onEq uip P rocess
R efix tu reP ick fromE qu ip
R em ove fromW k stn
E xitS hop
P ut onEq uip
D elive r toW ks tn
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Material Processor System Model
O utput Input
Process ing
2 13
NC M achineEquipm ent Type: M PNam e: NC M illPart Locations:Num P rocessing B locked Input Output 1 N N Y N 2 Y Y N N 3 N N N Y
M P :m p_put p rocess m p_p ick
Physical Model
Physical Configuration
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Material Handler System Model
M H :pu tp ick
Home Equipment Type: MHName: M1-L RobotGripper Capacity: 1Locations: 20 - Home: 0Num x y z1 0 0 0: : : :20 100 100 100
Physical Model
Physical Configuration
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Typical Processing Workstation
Horizon VVertica l M ill
Da e woo Pu m aTu rn ing Ce n te r
Bu ffer
Fan uc M 1-L
M ate ria l T ra nspo rtCar t
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Physical Model - Processing Workstation
S
po rt_ a rr ive
po rt_p ickport_depart
bs_pick bs_put
port_put
E
P o rt M H
B S
m p_ pickm p_put
M P
m p_ pick
m p_put
M P
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Event SequenceEvent Source Message/
TaskDestination
1 Workstation assign part machine controller2 Machine Controller at location workstation3 workstation put part robot controller4 robot controller put task robot5 robot controller put done workstation6 workstation grasp part machine controller7 machine controller grasp part
taskmachine
8 machine controller grasp done workstation9 workstation clear robot controller10 robot controller clear task robot11 robot controller clear done workstation12 workstation clear OK machine controller
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Equipment-level Device Interaction
ro b o t c le a r
e x e c u te p ro g ra mto c lo s e fix tu re
fix tu re c lo s e d
e x e c u te p a r tp ro g ra m
c le a r to lo a d p a rt ?
e x e c u te p ro g ra mto lo a d p a rtc lo s e fix tu re
e x e c u te p ro g ra m to re le a s e p a rt a n d
m o v e a w a y
c le a r
mp_put
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Can this be implemented in a generic manner?
Custom specifics Protocols Communications
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Message-based Part State Graph (MPSG) An MPSG is a deterministic finite automaton
representing the processing protocol for a part.
An MPSG state provides information about the current processing state of the part that is needed to determine the behavior on subsequent events.
State transitions are caused by receiving messages about the part and by performing functions specified by the scheduler.
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A Mealy machine is essentially a finite automaton with output. Formally, a Mealy machine M is defined as follows:
So, a Mealy machine is a finite state automaton in which an output (defined by and ) is generated during state transitions.
Mealy Machine
M Q q
Q q
Q
, , , , , ,
, , , ,,
:
0
0
where
and are as is in a finite automaton,is an output alphabet and
is an output transition function.
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MPSG Definition
function.nsition action tra controller a is )(:functionn transitiostate a is )(:
false.or truereturns which predicate a is each e,Furthermor . ingcorrespond a is there,each for that so
dpartitione is actions. controllerfor onspreconditi physical ofset finite a is
action controller some performswhich function executablean is whereactions controller ofset finite a is
taskscontroller ofset a is messagesoutput ofset a is
messagesinput ofset a is and events, ofset finite a is )(
states acceptingor final ofset a is statestart or initial theis
states ofset finite a is :Where
),,,,,,,(=MPSG
0
0
TO
TOI
T
O
I
TOI
QQQ
QFQq
Q
FqQ
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MPSG for Generic MP Equipment
ass ign _w e t_ass ign @ loc_ew
@ loc_ns_ew
grasp_we t_grasp grasp_ok_ew clea r_ok_we
m p_ pu t
1 2 3 4 5 6 70
proc esst_sta rt
t_s top
t_dnld
fin ish_de done_ew
t_start
t_dn ld
done_ew
7 8 9 10
re lea se_ok_ew@ loc_ew
@ loc_ns_ew
clear_ok_werem ove_we t_ rem ove re lease_we t_re lease
m p_ pick
10 11 12 13 14 15 16 17
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MPSG Characteristics Explicitly separate scheduling from execution.
Extensible at multiple levels to facilitate software development
Generic MPSG can be used unmodified. Extraneous transitions can be removed. Specified messages and tasks can be rearranged. New messages and tasks can be specified.
Execution portion of the control software is automatically generated from the MPSG description.
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Storage Class Provides basic database functions for
the controller Parts are tracked based on their location in the
shop, state, and the workstation and equipment level device to which they are assigned.
Objects within the storage class Parts Slots - Corresponding to physical locations Entities - Lower level controllers in the control
hierarchy
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Controller Class Embellishes the storage class with
the data structures necessary for control.
U ser In terface
C om m un ic a tion s
M P S G
P lan ner
S ched u ler
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Equipment Class Specializes the controller class so that
the instantiated objects interact directly with a piece of equipment
Not “Equipment Objects” in the system. Rather the equipment class is further partitioned based on the behavior of the individual pieces of equipment.
Material Processors (MP) Material Handlers (MH) Automated Storage Devices (AS) Material Transporters (MT)
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Software Generation Generation software has been
developed in C++ for use in DOS, OS/2, ULTRIX, AIX, UNIX and Windows operating system environments.
Components of the generation system MPSG Builder Controller Class
MPSG Class Communications Class (IOMUX for CIM lab implementation)
Generic equipment descriptions and functions MPSG Scheduler Task action functions
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Communication Controller to device Controller to controller Controller to database Controller to Messaging
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Communications - continued IOMUX
1995 based system that connected all of the computers
Router 1997 based system that uses a single
device to route all messages
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IOMUX (I/O Multiplier) Facilitates the interprocess transfer of
data in a consistent manner independent of the hardware/operating systems of the components.
System components can be reconfigured without recompilation by modifying an ASCII configuration file representing the route map (default.map).
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Platform/domain Formerly implemented on the
following platforms: DOS
RS-232 Serial TCP/IP using Watt TCP
OS/2 TCP/IP Shared queues (IPC)
UNIX - TCP/IP DEC ULTRIX IBM AIX SGI
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Current Implementation Windows NT/ Windows 2000 serves
as the core for the system. Arena 3 or 4 is used as message
generation for the Execution system
Router – communication Access - database
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Shop Level Physical Model
p u t
p ic k
M P 1
M H 3M H 2M H 1
P 1 P 2 P 3
m ov e
m ove
m o v e
m o v e
p ic k
p ic k
p ic k
p ic k
p ic k
p ic k
p u t
pu tp u t p u t
p u t
p ro c e s s p ro c e ss p ro c e s s
M P 2 M P 3
s to re re trie v e
A S 1
A S 1
Start/Stop
introduce
remove
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Controller Tasks Physical Model actions/tasks become tasks
issued by simulation
Simulation - issues a “pick” through a message placed in the task initiation queue
Big Executor explodes the “pick” task into various messages that
are send to the individual controllers and co-ordinates their actions based on the responses
returns a “pick_done” message to the simulation in the task completion queue
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Conclusions Traditional Control Software generation
issues Concept of RapidCIM Separation of Planning and Execution Physical models for equipment classes Workstation and shop level controllers
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What Next? Manufacturing Architectures RapidCIM Simulation-based Control NEXT! Implementation Issues
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Resources Joshi, S. B., Mettala, E. G., Smith J. S., and Wysk, R. A., “
Formal models for control of flexible manufacturing cells: physical and system model”, IEEE Transactions on Robotics and Automation, v11, n4, Aug, 1995 IEEE, Piscataway, NJ, USA, p 558-570.
Joshi, S., J. Smith, R. Wysk, B. Peters, and C. Pegden, "Rapid-CIM: An
Approach to Rapid Development of Control Software for FMS Control", 27th CIRP International Seminar on Manufacturing Systems, Ann Arbor, MI, May, 1995.
Mettala, E. G., “Automatic generation of control software in computer-integrated manufacturing”, Ph.D. Dissertation, Department of Industrial and Manufacturing Engineering, Pennsylvania State University, University Park, PA 16802, 1989.
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Resources Qui, R. B., “Modeling and Control of a flexible manufacturing system
using deterministic finite capacity automata”, Ph.D. Dissertation, Department of Industrial and Manufacturing Engineering, Pennsylvania State University, University Park, PA 16802, 1996.
Qui, R. B. and Joshi, S. B., “
Deterministic finite capacity automata: a solution to reduce the complexity of modeling and control of automated manufacturing systems”, Proceedings of the 1996 IEEE International Symposium on Computer-Aided Control System Design, Sep 15-18 1996, Dearborn, MI, USA, p 218-223
Qui, R. B. and Joshi, S. B., “A Structured Adaptive Supervisory Control Methodology doe Modeling the Control of Discrete Event Manufacturing” IEEE Transactions on Systems, Man, and Cybernetics, vol. 29, no. 6, 1999, pp. 573-586