the cybernetic factory- - ibtc · the cybernetic factory-from research work to re-structuring the...

The Cybernetic Factory-From Research work to

Re-structuring the department

Adaptable Production Systems,

The development

• Starting in 2002, a group of European researchers set out to prove that Flexible Automation was not succeeding.

• They proposed the Evolvable Production Systems paradigm (EPS).

• Learning is the basis of adaptation. These EPS systems could learn and adapt. They were modular and had their own controllers.


Evolvable Production

• one process = one system module

• all product processes = an assembly system of individual modules

• each module has its own controller (mechatronic)

• distributed control and not hierarchical

• zero change-over time

• radically lower costs

Instantly Deployable Evolvable Assembly SystemsCP-FP 246083-2 IDEAS

By 2012 the EPS group could demonstrate one of the first Plug & Produce systems in the world.


Adaptable Production Systems,Industriell Produktion

Mauro Onori, KTH, Oct.2013

The PARTNERS:

KTH, Sweden

UNINOVA, Portugal

UNIVERSITY of NOTTINGHAM, Great Britain

KARLSRUHE INSTITUTE of TECHNOLOGY, Germany

FESTO AG, Germany

ELREST GmbH, Germany

CENTRO RICERCHE FIAT, Italy

ELECTROLUX SpA, Italy

MASMEC SpA, Italy

TEKS SrL, France

The Module Concept

• The most important concept in a EAS is the concept of Module.• Basic building block.• A module is an intelligent process oriented entity able to be

aggregated.– It has a functionality or skill – It is autonomous since it includes computational power– It is inherently distributed– Must have the functionalities to be able to interconnect to create

complex entities• Mechanical interfaces• Control interfaces

• A module is characterised by its skills. They represent product needs.

• The module has a set functionality. It is dedicated.

Self-organisation

Manufacturing Components– are agentified (even old ones)

Coalition– group of agents that represent

manufacturing components– The behaviour is regulated by a

multilateral contract

Cluster– group of agents that can cooperate (for

instance, because they have spatial relationships)

– The behaviour is regulated by a cluster adhesion contract

Broker– To create and delete consortia

SCARA

ROBOT

Tool Warehouse

Too

l Wa

reh

ou

se

Sensor+Stopper

Positioning DevicePallet with Assembly Gabarit Pallet with Intermediate Product

Pallet with Raw MaterialPallet with

Finished Product

Antropomorphic

Robot

Wa

reh

ou

se

SCARA

ROBOT

Tool Warehouse

Pallet with Intermediate Product

To

ol W

are

ho

use

Antropomorphic

Robot Too

l Wa

reh

ou

se

Sensor+Stopper

Positioning DevicePallet with Assembly Gabarit

Antropomorphic

Robot

First system: FESTO Esslingen, November 2011Medical application

The Industrial Systems


The Industrial Systems

Second system: MASMEC SpA, Bari, June 2013ECU assembly for IVECO

Manual Loading Station Assembling Station

Leak Tests Station

FESTO Labeling Stations

Manual Unloading Station

Automatic Unloading Station

The “Academic” Systems

KTH, Stockholm:Electrolux washing machine feet assembly

UNINOVA, Portugal: 3 systems.

1. system built from legacy components (BOSCH, ABB, etc.)2. System built with FESTO components3. educational system built with….Fischer Teknik!

HOW?

①Development of a very generic, simple Mechatronic Architecture

②Development of an IDEAS agent development environment

③Development of new commercial controllers

④Development of software tools

⑤Making it all fit together!

HOW?

The Mechatronic Architecture

HOW?

IDEAS Agent Development Environment, IADE:

This is the “operating system” of ourP&P solution.

NOTE the 4 software tools.

IADE CORE

Workflow and Process Design

Tools

Inte

rfac

e

Visualization Tools

InterfaceModule Design

ToolsInterface

Simulation ToolsIn

terf

ace


HOW?

New commercial controllers for multi-agent applications (ELREST GmbH)

Controllers comeIn 3 variants,depending on computationalpower needs.


The “software tools” have been the most demanding aspect.

Repeating these installations in industry requires application tools.All tools are to be integrated into one User Interface Tool, the Configurator. Includes Virtual Machine simulator.

HOW?

Eng. G.Triggiani - MASMEC

AUTOMATION ML IN KTH CONFIGURATION TOOL -1/3-

Bari, June, 25th 2013Eng. G.Triggiani - MASMEC

PRE DEMONSTRATOR TEST CASE

Bari, June, 25th 2013

HOW?The importance of using STANDARDS.

The IDEAS project used de-facto standards all through the project in order to ensure industrial applicability.

JAVA for agent development.JADE for the environment.FIPA protocols.COLLADAetc

Automation ML-• CAEX (IEC 62424) for describing industrial automation system topology as a hierarchical structure of the objects. • COLLADATM for describing 3D geometry of the objects, physical interconnection of 3D objects and geometric dependencies to support motion planning. • PLCopen XML for describing the behavior of objects and the automation system in a sequence of actions including the corresponding I/O relations and logical variables.

Eng. G.Triggiani - MASMEC -

• CAEX (IEC 62424) for describing industrialautomation system topology as a hierarchicalstructure of the objects used in theautomation system (their properties andrelations). This structure is theAutomationML top level format.

• COLLADATM for describing 3D geometryof the objects, physical interconnection of 3Dobjects and their geometric dependencies tosupport motion planning. This information isstored in a separate XML file.

• PLCopen XML for describing the behaviorof objects and the automation system in asequence of actions including thecorresponding I/O relations and logicalvariables.

AUTOMATION ML ARCHITECTURE -1/2-

Bari, June, 25th 2013



WHY ?

Sustainability: we no longer need to BUY system components-They are RE-USABLE, so may be hired/leased.

Economic: stepwise upgrade/automation, lease not buy, linked to product. Business Model available.

Social: demography shows we must automate. We must make automation cost-effective.

Technological: it is fully feasible and technology is even further ahead. We only need to translate it into production applications.

Volumes/ Demand

Co

stTi

me

Intr

od

uct

ion

Dev

elo

pm

en

tM

atu

rity

i = 0 i = 2 i = 3i = 1 i = N

T1

T2

T3

TN-1

V1 V2 V3 VN-1

--- i = ... ---

Calculation of the economically optimal instants Ti

of deployment for the (i+1)th automatic station

What did we discover whilst working together?

- Society has changed- The world needs attention- People have new attitudes

- How do we organise ourselves to cater for this New World?


Resources

Resource exploitation Re-usability Customer participation Quality or quantity...?


Environment

How is the user/customer involved with the product??

New appraches to ownership...

”Prosumers”

Can we keep producing at the rate we do today??


Water scarcity is becoming the

strongest threat to world

peace.

Aral sea

Colorado river

Yangtse river

Consumer to Prosumer

Global connectivity

“Prosumers”- ability to sell energy, parts, services

Growing global middle-class

More informed than ever, more aware

Young generation is born and educated within

technological era; does not view ownership as us


People’s approach to products

1. MUST be eco-sustainable

2. Sharing rather than buying

3. Re-engineering of complex products rather

than throwing away

=> REQUIRE NEW BUSINESS MODELS, NEW

PROCESSES


TECHNOLOGY

Beyond the “Internet of Things” or “Ind.4.0”…

The biggest change in technology in the past 10-15 years is not the Internet alone. • It is the power of computer software and its ability to

cooperate and evolve.

• Programs used to be event-driven (if-then-else).They follow behaviours now (attributes).

• Process-oriented system design & development has optimised functionality and enables the good use of IT


Forming the Vision: Driver-What solution-HOW

The Vision

Technology solution

Social opportunity

Economic Impact

Ecological balance

• Regenerative processes• Re-usable systems• Autonomous control• Product-process integration

• Material re-use, energy saving• New human-machine approaches• New stakeholders, new companies• Multi-disciplinary schools

• Business models• Stepwise investment• Quality approaches• New technology-investment schemes

• Disassembly vs Additive Mfg.• Ecology in cost equation• Energy efficient production• …

ROADMAP


Roadmap 2050 Adaptable Production Systems,Industriell Produktion

Computer Systems for design and manufacturing(Prof.Torsten Kjellberg)

Evolvable Production SystemsProf.Mauro Onori

Production SystemsProf.Bengt Lindberg

MetrologyProf.Lars Mattsson

Machine & Process TechnologyProf. Mihai Nicolescu

Sustainable ManufacturingProf.Lihui Wang

Department Units in 2013 Adaptable Production Systems,Industriell Produktion

Summarising: Opportunities

1. Internet is not new. It is how we will empower it that may be new.

2. Distributed control systems are here to change our applications.

3. Adaptive/adaptable systems are more robust due to the focus on set, specific processes!! Embedded sensors enhance this.

4. Big Data or no big data, the Cloud will have an enormous impact and it will change our business view.

5. We need new business models and a new economic paradigm.

6. Start thinking ETHICS. Our values define our world.


THE VISION

Human in full symbiosis with machines

Re-usable equipment and resources

Energy & resource efficiency

Circular economic approach

Full data integration and information flow

New, sustainable manufacturing processes

New educational programmes

THE CYBER-ETHICAL FACTORY


Today

Mauro Onori, KTH, May 2014

IIP, Production Engineering

Technologies for Adaptable Production

Prof. Onori Asst.Prof. Maffei Dr. Akillioglu Dr.Sivard

Prof. Wang Asst.Prof. Assoc.Prof. Prof. LindbergX. Wang Semere

Prof.Mattsson Asst.Prof.Archenti Assoc.Prof. Prof. Rashid Nicolescu

Adaptable Prod. Systems

Demand Responsive

Planning

Business Models

Digital Factory

PrefektMauro Onori


Thank you.

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