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Eastern Mediterranean University

Eastern Mediterranean University. Faculty of Engineering. Department of Mechanical Engineering. Reconfiguring Real-time Holonic Manufacturing System. Presented By:. Reza ABRISHAMBAF. Faezeh YEGANLI. Real-time HMS. Agenda. Introduction IEC 61499 Function Block

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Eastern Mediterranean University

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  1. Eastern Mediterranean University Faculty of Engineering Department of Mechanical Engineering Reconfiguring Real-time Holonic Manufacturing System Presented By: Reza ABRISHAMBAF Faezeh YEGANLI

  2. Real-time HMS • Agenda • Introduction • IEC 61499 Function Block • Holonic Manufacturing System • Real-time Distributed Control System • Reconfiguration of Real-time Distributed Control • Case Study • Application of Virtual Reality • Prepared By:Abrishambaf, Yeganli

  3. Real-time HMS • Introduction • Manufacturing control systems are required to be adaptive and responsive. • One approach which is closely related to the Multi-agent systems is HMS. • The motivation is the requirement for manufacturing systems that can automatically and intelligently adapt to changes in the manufacturing environment while still achieving overall system goals. • Prepared By:Abrishambaf, Yeganli

  4. Real-time HMS • Introduction • At the low control level of a HMS, especially at the level of real-time control, reconfigurable holonic controllers are employed (HCs). • The critical issue for holonic control at this level is how the resources of the HMS are to be organized dynamically during runtime and how the associated controller components are to be reconfigured dynamically at the same time. • Solution: • Real-time distributed control system that can benefits of holonic control system. • Prepared By:Abrishambaf, Yeganli

  5. Real-time HMS • Introduction • The real-time holonic distributed control systems require: • Stability in the face of disturbance (i,e., Sensor or Robot Failure.) • Adaptability and flexibility in the face of change. • Efficient use of available resource. • To do so, IEC-1499 Function block (FB) standard is employed. • Let’s have a look at PLC first!! • Prepared By:Abrishambaf, Yeganli

  6. Real-time HMS • Introduction • A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of mechatronic processes, such as control of machinery on factory assembly lines. • Designed for Multiple Input Multiple Output (MIMO). • Fixed I/O or Modular I/O • Prepared By:Abrishambaf, Yeganli

  7. Real-time HMS • Introduction • SIEMENS S7-200, CPU 222. • 8 Inputs, 6 Outputs. • 256 Counters & Timers. • Prepared By:Abrishambaf, Yeganli

  8. Real-time HMS • Introduction • Prepared By:Abrishambaf, Yeganli

  9. Real-time HMS • IEC-61499 Function Block • A standardization project of IEC Technical Committee 65 (TC65) to standardize the use of function blocks in distributed industrial-process measurement and control systems (IPMCSs). • Work item approved 1991; assigned to Working Group 6 (WG6) 1993 • Experts from USA, Germany, Japan, UK, Sweden, France, Italy • Also responsible for IEC 61131-3 (Programmable Controller Languages) and 61131-8 (Programmable Controller Language Guidelines) • Prepared By:Abrishambaf, Yeganli

  10. Real-time HMS • IEC-61499 Function Block • Distributed applications • Event and data interfaces • Software encapsulation and reuse • Event-driven state machines • Service interfaces • Management services • Software portability • Prepared By:Abrishambaf, Yeganli

  11. Centralized ProgrammableConfigurable PLCIEC 61131-3 agility! distributability Thesis Antithesis programmability DCS IEC 61804 agility! Distributed Configurable Real-time HMS • IEC-61499 Function Block dynamically reconfigurable= agile ! Common ArchitectureReferenceModel Function Blocks IEC 61499 Synthesis distributed configurable programmable • Prepared By:Abrishambaf, Yeganli

  12. Real-time HMS • IEC-61499 Function Block • IEC 61499 is composed of 2 IECs standards: IEC-61131-3 and IEC-61804. • IEC-61131-3 is Centralized Programming Configurable (PLC) with Distributablity property. • IEC-61804 is Distributed Configurable with Programmibility property. • The result is Distributed Configurable Programmable which is common architecture reference model. • Prepared By:Abrishambaf, Yeganli

  13. Requirements Controls architecture Intelligent Automation architecture Real-time HMS • IEC 61499 • Parent organization: IEC • Working group: TC65/WG6 • Goal: Standard model (function blocks) for control encapsulation& distribution • Started: 10/90 • Active development: 3/92 • Trial period: 2001-03 • Completion: 2005 • Holonic Manufacturing Systems (HMS) • Parent organization: IMS • Working group: HMS Consortium • Goal: Intelligent manufacturing through holonic (autonomous, cooperative) modules • Feasibility study: 3/93-6/94 • First phase: 2/96 - 6/00 • Second phase: 6/00-6/03 • Prepared By:Abrishambaf, Yeganli

  14. Real-time HMS • IEC-61499 Function Block Event inputs Event outputs Execution Control Chart Type identifier Algorithms (IEC 1131-3) Internal variables Input variables Output variables • Prepared By:Abrishambaf, Yeganli

  15. Real-time HMS • IEC-61499 Function Block • Function Block is consist of two main parts: Head and Body. • The head of Function Block is Execution Control Chart (ECC) which organizes the flow of events between the blocks as well as the body control. • The body of Function Block consists of algorithm and the internal data as well as the I/O data. • The algorithm inside the body operates in IEC-61131-3 standards. • The body will control the resource capabilities, scheduling, communication and process mapping. • Events inputs and outputs are used to synchronize function blocks within an application and to schedule the algorithms within the function block. • Data inputs and outputs are the interface with the external of the function block since internal data is hidden. • Prepared By:Abrishambaf, Yeganli

  16. Real-time HMS • IEC-61499 Function Block Function Block Execution Model • Prepared By:Abrishambaf, Yeganli

  17. Real-time HMS • IEC-61499 Function Block • Relevant data input values are made available. • The event at the event input occurs. • The execution control function notifies the resource scheduling function to schedule and algorithm for execution. • Algorithm execution begins. • The algorithm completes the establishment of values for the output variables associated with the event output. • The resource scheduling function is notified that algorithm execution has ended. • The scheduling function invokes the execution control function. • The execution control function signals an event at the event output. • Prepared By:Abrishambaf, Yeganli

  18. Real-time HMS • Holonic Manufacturing System • Holon is an autonomous and cooperative building block of a manufacturing system for transforming, transporting, storing, and/or validating information and physical objects. • Holon Autonomy is the capability of a holon to create and control the execution of its own plans and/or strategies. • Holon Cooperation is the process whereby a set of holons develops mutually acceptable plans and executes them. • Holon Self-organization is the ability of holons to collect and arrange themselves in order to achieve a production goal. • Holarchy is system of holons that can cooperate to achieve a goal or objective. • Prepared By:Abrishambaf, Yeganli

  19. Real-time HMS • Real-time Distributed Control (Definitions) • System: A collection of devices interconnected and communicating with each other by means of a communication network consisting of segments and links. • Device: An independent physical entity capable of performing one or more specified functions in a particular context and delimited by its interfaces. • Resource: A functional unit having independent control of its operation, and which provides various services to applications including scheduling and execution of algorithms. • Application: A software functional unit that is specific to the solution of a problem in industrial-process measurement and control. An application may be distributed among devices and may communicate with other applications. • Prepared By:Abrishambaf, Yeganli

  20. Real-time HMS • Real-time Distributed Control • A holon is represented by one or more hardware devices and can interact via one or more communication networks. • Each device comprises of one or more resources (i.e. processor with memory) and one or more interface. • Interfaces enable the device to interact with either the controlled manufacturing process or with other devices through a communication interface. • Resources are logical entities with independent control over their operations including the scheduling of their tasks. • A resource can be created, configured via management model. • Prepared By:Abrishambaf, Yeganli

  21. Real-time HMS • Real-time Distributed Control • Applications are networks of function blocks (FB) and variables connected by data and event flows. • Such applications aid the modeling of cooperation between the autonomous holons. • Function blocks receive event/data from interfaces, process them by executing algorithms and produce outputs, all handled by an event control chart. • Function block algorithms can be written in high-level programming language or in the IEC-61131 language for PLCs. • Prepared By:Abrishambaf, Yeganli

  22. Real-time HMS • Reconfiguration of Real-time Distributed Control • In conventional PLC systems, reconfiguration involves a process of first editing the control software offline while the system is running, then committing the change to the running control program. • When the change is committed, severe disruptions and instability can occur as a result of high coupling between elements of the control software and inconsistent real-time synchronization. • Three types of reconfiguration: • Simple configuration utilizes the IEC 61499 model to avoid software coupling issues during reconfiguration. • Dynamic reconfiguration uses techniques to properly synchronize software during reconfiguration. • Intelligent reconfiguration exploits multi-agent techniques to allow the system to reconfigure automatically in response to change. • Prepared By:Abrishambaf, Yeganli

  23. Real-time HMS • Reconfiguration of Real-time Distributed Control The Reconfiguration Model • Prepared By:Abrishambaf, Yeganli

  24. Real-time HMS • Reconfiguration of Real-time Distributed Control • Function block ports (i.e., event and data connections) are objects that register with the Resource Manager (RM) associated with the function block. The resource manager looks after the interconnection of function block ports (i.e., as is specified by the application) and maintains a record of all function block ports in a FB Port table. • The Device Manager (DM) looks after the interconnection of the RM’s function block ports and stores this information in an RM Port table. • Application Manager (AM) looks after the interconnection of the DM’s function block ports and stores this information in a DM Port table. • Prepared By:Abrishambaf, Yeganli

  25. Real-time HMS • Reconfiguration of Real-time Distributed Control • The advantage of this approach is that reconfiguration can be managed at various levels (i.e., function block, resource, device, application); all that is • required is a “map” of the new configuration (i.e., based on the FB, RM, and DM Port tables). • This approach allows for the “basic reconfiguration” discussed previously, but does not yet address how dynamic and intelligent reconfiguration are performed. • The fundamental difference between basic and dynamic reconfiguration is the latter’s recognition of timeliness as a critical aspect of correctness. • Prepared By:Abrishambaf, Yeganli

  26. Real-time HMS • Reconfiguration of Real-time Distributed Control • Intelligent reconfiguration builds .on dynamic reconfiguration (i.e., timeliness constraints) by focusing on multi-agent techniques to allow the system to reconfigure automatically in response to change. • For example, as part of a fault recovery strategy, higher-level agents will manage the reconfiguration process using diverse or homogeneous redundancy. • Two approaches to achieve these more advanced forms of reconfiguration: • Preprogrammed or “contingencies” approach. • Softwiring approach. • Prepared By:Abrishambaf, Yeganli

  27. Real-time HMS • Reconfiguration of Real-time Distributed Control • Contingencies Approach • Contingencies are made for all possible changes that may occur. • Alternate configurations are pre-programmed based on the system designer’s understanding of the current configuration, possible faults that may occur as well as possible means of recovery. • Disadvantages: • Inflexibility particularly with respect to the handling of unanticipated changes. • This approach would require constant maintenance in order to keep the reconfiguration tables up to date. • Prepared By:Abrishambaf, Yeganli

  28. Real-time HMS • Reconfiguration of Real-time Distributed Control • Soft-wiring Approach • FB, RM, DM port tables are connected to the Configuration Agent (CA). • This agent has information of how two FB, RM or DM can be connected. • CA will use this information, for example, to connect a new function block with an existing function block or to replace an existing one with a new while ensuring that the real-time requirement are met. • Advantages: • It’s potential to overcome the inflexibility • It’s potential to realize intelligent reconfiguration. • Prepared By:Abrishambaf, Yeganli

  29. Real-time HMS • Case Study System 1 Conveyor 5-joints Robot Barcode Reader Infrared Sensor • Prepared By:Abrishambaf, Yeganli

  30. Real-time HMS • Case Study • System 1 contains Conveyor, Robot, Barcode Reader and Sensor. • At the beginning of the conveyor, there is a switch. When a part touch the switch, the conveyor will start. • When a part comes to the system, it will be moved by conveyor. There is a barcode reader will read the code of the part. • Depending on the code of the part, the Robot will put it in either Machine 1 or Machine 2 or to the Conveyor 2 of the system 2. • Prepared By:Abrishambaf, Yeganli

  31. Real-time HMS • Case Study System 2 Conveyor 5-joints Robot Pneumatic Robot Color Sensor Infrared Sensor • Prepared By:Abrishambaf, Yeganli

  32. Real-time HMS • Case Study • System 2 contains Conveyor, Robot, Pneumatic Robot, Color Sensor and Infrared Sensor. • The system waits until a part from system 1 arrives. • When infrared sensor detects a part, the conveyor will start. • Part will be moved till the color sensor, beside the color sensor, we have pneumatic robot that will take the part or it will be moved until the infrared sensor detects it. • By detecting with infrared sensor, the robot will take and put the part in another machine. • Prepared By:Abrishambaf, Yeganli

  33. Real-time HMS • Prepared By:Abrishambaf, Yeganli

  34. Real-time HMS • Case Study (Reconfiguration) Adding a Robot Configuration Agent Cell 2 CA Cell 1 Robot • Prepared By:Abrishambaf, Yeganli

  35. Real-time HMS • Case Study • Case Study (Reconfiguration) • Methods of Adding a Robot • To use the common method (Offline Mode). • To use the predicted table. • To use the IEC 61499 FB Standard. • Prepared By:Abrishambaf, Yeganli

  36. Real-time HMS • Case Study • Case Study (Reconfiguration) • Adding a Robot • The aim is to add one Robot the system. • Cell 1 & Cell 2 have their own Function Blocks (FB1, FB2,….). • Function blocks will have information on how they can be connected (i.e., their interfaces) that is stored by CAS. The CAS will use this information, for example, to connect a new function block with an existing function block or to replace an existing function block with a new one while ensuring that the application’s real-time requirements are met during the reconfiguration process. The primary advantage of this approach is its potential to overcome the inflexibility of the contingencies approach as well as its potential to realize intelligent reconfiguration. • Prepared By:Abrishambaf, Yeganli

  37. Real-time HMS • Case Study • Case Study (Reconfiguration) For example, if the request for a new configuration requires upgrading an application to include more sophisticated functionality, and the device does not have sufficient processing resources for this upgrade, the new functionality may have to be out-sourced. Moreover, even if the execution of the function blocks’ tasks are consistent with the device’s schedule and equipment, the device actor might still decide to out-source some or all of the new configuration’s tasks. For example, this redistribution may be done to save some of the available resources for executing tasks associated with a configuration that is currently under negotiation with the user. • Prepared By:Abrishambaf, Yeganli

  38. Real-time HMS • Application of Virtual Reality • In this section three simulation softwares will be presented. • Virtual Reality • Rockwell Simulation Model • MAST (Manufacturing Agent Simulation Tool) • Prepared By:Abrishambaf, Yeganli

  39. Real-time HMS • Application of Virtual Reality • Prepared By:Abrishambaf, Yeganli

  40. Real-time HMS • Application of Virtual Reality • The Design Environment includes the Multi Agent System Model. • The agents are AGVs, Robots, Conveyor,… • The messaging system is based on JAVA/JADE. • What if each agent is defined based on IEC 61499 Function Block? FB FB FB Conveyor AGV Robot • Prepared By:Abrishambaf, Yeganli

  41. Real-time HMS • Application of Virtual Reality Proposed Multi Agent System Based on IEC 61499 Configuration Agent Header Header Header Body Body Body AGV Robot Conveyor • Prepared By:Abrishambaf, Yeganli

  42. Real-time HMS • Application of Virtual Reality • The agents are defined based on IEC 61499 FB. • The headers of Function Blocks are connected to the Configuration Agent. • The Configuration Agent (CA) contains the status of each Function Block and the connection among them. • This configuration system can be based on JAVA/JADE or other high level languages. • In case of device failure, since CA has the status of the FBs, it can substitute another device instead. • The whole system is in the Design Environment. • Prepared By:Abrishambaf, Yeganli

  43. Real-time HMS • Application of Virtual Reality A holon is represented by one or more hardware devices, and can interact via one or more communication networks. Each device comprises of one or more resources (i.e., processor with memory) and one or more interfaces. Interfaces enable the device to interact with either the controlled manufacturing process (via a process interface) or with other devices through a communication interface. Resources are logical entities with independent control over their operations including the scheduling of their tasks. A resource can be created, configured etc (as part of the system’s life-cycle) via a management model. • Prepared By:Abrishambaf, Yeganli

  44. Real-time HMS • Application of Virtual Reality Applications (software functional units spanning one or more resources and over one or more devices) are networks of function blocks (FB) and variables connected by data and event flows. Such applications aid the modeling of cooperation between the autonomous holons. Function blocks receive event data from interfaces, process them by executing algorithms and produce outputs, all handled by an event control chart. Function blocks’ algorithms can be written in either high-level programming languages (e.g., C++) or in the IEC 61 131 languages for programmable controllers (e.g., Ladder Diagrams, Structured Text). A distribution model controls how applications are decomposed while ensuring that every function block is an atomic unit of distribution. • Prepared By:Abrishambaf, Yeganli

  45. Real-time HMS • Application of Virtual Reality Another Simulation Model proposed by Rockwell Co. It represents a new approach to the manufacturing oriented agent based control and simulations that enables the integration of agents with the currently used industrial control hardware architecture and simplifies the transfer of the agent-control developed initially for simulation purposes to the actual physical control. • Prepared By:Abrishambaf, Yeganli

  46. Real-time HMS • Application of Virtual Reality • Physical Process: is the physical entity like AGV, Robot. • PLC: contains Data Table which has the status of each physical entity in the Tags(A1_tagA, A1_tagB). • Agent Control: contains the corresponded Physical Component Agent. • Emulation: used to simulate the system , like Matlab, Arena. • Visualization: providing graphical view of the system. • By the combinations of the mentioned blocks, an Agent Based Simulation System will be obtained. • Prepared By:Abrishambaf, Yeganli

  47. Real-time HMS • Advantage of Virtual Reality • One of the important advantages of such a real time system is that the system can be reconfigured online. • For instance, when a new sensor is added at runtime to the conveyor based • transportation system, a set of new elements are dynamically created and added to corresponding subsystems sharing the data-table: the sensor agent is added to the agent control part, the sensor emulation unit is added to the emulation subsystem and the sensor visualization element is added to the visualization module. Concurrently, the tag values corresponding to the state of the sensor are added to the data-table to be shared by these new elements. • Prepared By:Abrishambaf, Yeganli

  48. Real-time HMS • Advantage of Virtual Reality • Another Advantage: • The important feature of the proposed interface is smooth shift of the control functionalities from the agent based simulation towards the real-life control. It allows replacing of the emulation subsystem with the real physical manufacturing equipment by preserving the same tag names referring to the sensor and actuator values. Thus it is not necessary to do any modifications in the agents or in the visualization subsystem. • Prepared By:Abrishambaf, Yeganli

  49. Real-time HMS • Application of Virtual Reality • MAST (Manufacturing Agent Simulation Tool) • As result of the research effort under the Intelligent Manufacturing Systems (IMS) framework Rockwell Automation in cooperation with different partners has designed and developed MAST (Manufacturing Agent Simulation Tool) a graphical visualization tool for multi agent systems. The main target is the materials handling domain and it is built on the JADE standard FIPA platform. In MAST, the user is provided with the agents for basic material handling components as for instance manufacturing-cell, conveyor belt, diverter and AGVs. The agents cooperate together via message sending using common knowledge ontology developed for material handling domain. • Prepared By:Abrishambaf, Yeganli

  50. Real-time HMS • Application of Virtual Reality • MAST (Manufacturing Agent Simulation Tool) • MAST represents the state of the art in graphical simulation tools for modeling and simulation of multi agent systems in manufacturing control, however and due to the fact that only material handling systems are targeted the tool does not cover complex application from a 3-D geometric viewpoint such as the robotic manipulation. • Prepared By:Abrishambaf, Yeganli

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