Planeamento e balanceamento de uma linha de montagem universal para formação

Este trabalho teve o intuito de criar uma linha de montagem universal através da qual será dada formação aos atuais operadores e a novos que possam vir a pertencer ao departamento de montagem na empresa Grohe Portugal. Para tal era necessário saber realizar um estudo de métodos e um estudo de tempos sobre os vários processos existentes no departamento de montagem. Com esse intuito foi elaborada uma pesquisa sobre as referidas temáticas, onde ficou evidente a sua importância e a sua imprescindibilidade. Inicialmente houve também um acompanhamento das montagens dos produtos nas várias linhas, de forma a adquirir conhecimento sobre as características dos processos de montagem existentes no departamento. Os pontos mais importantes durante o estudo de métodos e tempos realizado foram a definição de toda a estrutura do processo, das ferramentas e materiais a utilizar, não esquecendo a relação entre o operador e as suas ferramentas e a medição de tempos de todas as tarefas necessárias para cada processo de montagem. A linha de montagem, cujo projeto se desenvolveu, é composta por três bancadas e consiste num conjunto de postos de trabalho onde são executadas as operações através de máquinas, do trabalho humano, ou da sua conjugação, dispostos numa determinada sequência, sendo alguns deles amovíveis. Para a realização e conclusão deste projeto foram superadas diversas etapas, sendo que as mais relevantes foram:  a análise dos processos de montagem;  estudo de tempos de todas as famílias de produtos a serem implementados na linha de formação; - Definição da estrutura da linha de montagem; - Definição das rampas e dos tubos de abastecimento da linha; - Desenho da linha de montagem em 3D no software SolidWorks. Paralelamente foram também desenvolvidos estudos de tempos sobre alguns produtos com o intuito de serem implementadas melhorias, ou apenas para o controlo de tempos necessários para a realização das operações Por último, foi também elaborada uma recolha de ferramentas existentes no departamento de montagem para serem elaborados manuais de instruções das ferramentas fabricadas internamente, com o objetivo de obter a certificação OSHAS 180001 e de criar documentos com a listagem de materiais necessários para cada produto.

Supporting intra-task parallelism in real-time multiprocessor systems

Os sistemas de tempo real modernos geram, cada vez mais, cargas computacionais pesadas e dinâmicas, começando-se a tornar pouco expectável que sejam implementados em sistemas uniprocessador. Na verdade, a mudança de sistemas com um único processador para sistemas multi- processador pode ser vista, tanto no domínio geral, como no de sistemas embebidos, como uma forma eficiente, em termos energéticos, de melhorar a performance das aplicações. Simultaneamente, a proliferação das plataformas multi-processador transformaram a programação paralela num tópico de elevado interesse, levando o paralelismo dinâmico a ganhar rapidamente popularidade como um modelo de programação. A ideia, por detrás deste modelo, é encorajar os programadores a exporem todas as oportunidades de paralelismo através da simples indicação de potenciais regiões paralelas dentro das aplicações. Todas estas anotações são encaradas pelo sistema unicamente como sugestões, podendo estas serem ignoradas e substituídas, por construtores sequenciais equivalentes, pela própria linguagem. Assim, o modo como a computação é na realidade subdividida, e mapeada nos vários processadores, é da responsabilidade do compilador e do sistema computacional subjacente. Ao retirar este fardo do programador, a complexidade da programação é consideravelmente reduzida, o que normalmente se traduz num aumento de produtividade. Todavia, se o mecanismo de escalonamento subjacente não for simples e rápido, de modo a manter o overhead geral em níveis reduzidos, os benefícios da geração de um paralelismo com uma granularidade tão fina serão meramente hipotéticos. Nesta perspetiva de escalonamento, os algoritmos que empregam uma política de workstealing são cada vez mais populares, com uma eficiência comprovada em termos de tempo, espaço e necessidades de comunicação. Contudo, estes algoritmos não contemplam restrições temporais, nem outra qualquer forma de atribuição de prioridades às tarefas, o que impossibilita que sejam diretamente aplicados a sistemas de tempo real. Além disso, são tradicionalmente implementados no runtime da linguagem, criando assim um sistema de escalonamento com dois níveis, onde a previsibilidade, essencial a um sistema de tempo real, não pode ser assegurada. Nesta tese, é descrita a forma como a abordagem de work-stealing pode ser resenhada para cumprir os requisitos de tempo real, mantendo, ao mesmo tempo, os seus princípios fundamentais que tão bons resultados têm demonstrado. Muito resumidamente, a única fila de gestão de processos convencional (deque) é substituída por uma fila de deques, ordenada de forma crescente por prioridade das tarefas. De seguida, aplicamos por cima o conhecido algoritmo de escalonamento dinâmico G-EDF, misturamos as regras de ambos, e assim nasce a nossa proposta: o algoritmo de escalonamento RTWS. Tirando partido da modularidade oferecida pelo escalonador do Linux, o RTWS é adicionado como uma nova classe de escalonamento, de forma a avaliar na prática se o algoritmo proposto é viável, ou seja, se garante a eficiência e escalonabilidade desejadas. Modificar o núcleo do Linux é uma tarefa complicada, devido à complexidade das suas funções internas e às fortes interdependências entre os vários subsistemas. Não obstante, um dos objetivos desta tese era ter a certeza que o RTWS é mais do que um conceito interessante. Assim, uma parte significativa deste documento é dedicada à discussão sobre a implementação do RTWS e à exposição de situações problemáticas, muitas delas não consideradas em teoria, como é o caso do desfasamento entre vários mecanismo de sincronização. Os resultados experimentais mostram que o RTWS, em comparação com outro trabalho prático de escalonamento dinâmico de tarefas com restrições temporais, reduz significativamente o overhead de escalonamento através de um controlo de migrações, e mudanças de contexto, eficiente e escalável (pelo menos até 8 CPUs), ao mesmo tempo que alcança um bom balanceamento dinâmico da carga do sistema, até mesmo de uma forma não custosa. Contudo, durante a avaliação realizada foi detetada uma falha na implementação do RTWS, pela forma como facilmente desiste de roubar trabalho, o que origina períodos de inatividade, no CPU em questão, quando a utilização geral do sistema é baixa. Embora o trabalho realizado se tenha focado em manter o custo de escalonamento baixo e em alcançar boa localidade dos dados, a escalonabilidade do sistema nunca foi negligenciada. Na verdade, o algoritmo de escalonamento proposto provou ser bastante robusto, não falhando qualquer meta temporal nas experiências realizadas. Portanto, podemos afirmar que alguma inversão de prioridades, causada pela sub-política de roubo BAS, não compromete os objetivos de escalonabilidade, e até ajuda a reduzir a contenção nas estruturas de dados. Mesmo assim, o RTWS também suporta uma sub-política de roubo determinística: PAS. A avaliação experimental, porém, não ajudou a ter uma noção clara do impacto de uma e de outra. No entanto, de uma maneira geral, podemos concluir que o RTWS é uma solução promissora para um escalonamento eficiente de tarefas paralelas com restrições temporais.

The influence of inter-domain mobility on message stream response time in wired/wireless PROFIBUS-based networks

In previous works we have proposed a hybrid wired/wireless PROFIBUS solution where the interconnection between the heterogeneous media was accomplished through bridge-like devices with wireless stations being able to move between different wireless cells. Additionally, we had also proposed a worst-case timing analysis assuming that stations were stationary. In this paper we advance these previous works by proposing a worst-case timing analysis for the system’s message streams considering the effect of inter-cell mobility.

Anticipatory postural adjustments during sitting reach movement in post-stroke subjects

The study assessed the effect of velocity of arm movement on the generation of APAs in the contralateral and ipsilateral muscles of individuals with stroke in the sitting position. In the sitting position, 10 healthy and 8 post-stroke subjects reached for an object placed at the scapular plane and mid-sternum height at self-selected and fast velocities. Electromyography was recorded from the anterior deltoid (AD), upper (UT) and lower trapezius (LT), and latissimus dorsi (LD). Kinematic analysis was used to assess peak velocity and trunk displacement. Post-stroke subjects presented a delay of APAs on both sides of the body compared to healthy subjects. Differences were found between the timing of APAs on the ipsilateral and contralateral LD and LT in both movement speeds and in the ipsilateral UT during movement of the non-affected arm at a self-selected velocity. A delay in the contralateral LD in the reaching movement with the non-affected arm at fast velocity was also observed. Trunk displacement was greater in post-stroke subjects. In the sitting position, APAs were delayed in both fast and self-selected movements on both sides in post-stroke subjects, which also presented a higher trunk displacement.

A few what-ifs on using statistical analysis of stochastic simulation runs to extract timeliness properties

Modern real-time systems, with a more flexible and adaptive nature, demand approaches for timeliness evaluation based on probabilistic measures of meeting deadlines. In this context, simulation can emerge as an adequate solution to understand and analyze the timing behaviour of actual systems. However, care must be taken with the obtained outputs under the penalty of obtaining results with lack of credibility. Particularly important is to consider that we are more interested in values from the tail of a probability distribution (near worst-case probabilities), instead of deriving confidence on mean values. We approach this subject by considering the random nature of simulation output data. We will start by discussing well known approaches for estimating distributions out of simulation output, and the confidence which can be applied to its mean values. This is the basis for a discussion on the applicability of such approaches to derive confidence on the tail of distributions, where the worst-case is expected to be.

From simulation to statistical analysis: timeliness assessment of ethernet/IP-based distributed systems

A number of characteristics are boosting the eagerness of extending Ethernet to also cover factory-floor distributed real-time applications. Full-duplex links, non-blocking and priority-based switching, bandwidth availability, just to mention a few, are characteristics upon which that eagerness is building up. But, will Ethernet technologies really manage to replace traditional Fieldbus networks? Ethernet technology, by itself, does not include features above the lower layers of the OSI communication model. In the past few years, it is particularly significant the considerable amount of work that has been devoted to the timing analysis of Ethernet-based technologies. It happens, however, that the majority of those works are restricted to the analysis of sub-sets of the overall computing and communication system, thus without addressing timeliness at a holistic level. To this end, we are addressing a few inter-linked research topics with the purpose of setting a framework for the development of tools suitable to extract temporal properties of Commercial-Off-The-Shelf (COTS) Ethernet-based factory-floor distributed systems. This framework is being applied to a specific COTS technology, Ethernet/IP. In this paper, we reason about the modelling and simulation of Ethernet/IP-based systems, and on the use of statistical analysis techniques to provide usable results. Discrete event simulation models of a distributed system can be a powerful tool for the timeliness evaluation of the overall system, but particular care must be taken with the results provided by traditional statistical analysis techniques.

Integration of TCP/IP and PROFIBUS protocols

Recent technological developments are pulling fieldbus networks to support a new wide class of applications, such as industrial multimedia applications. These applications are usually supported by the widely used TCP/IP stack. It is thus essential to provide support to TCP/IP based applications, in fieldbus networks. This paper presents an effort that is being carried out to integrate the TCP/IP and PROFIBUS stacks, in order to support industrial multimedia applications, whilst guarantying the timing requirements of control-related traffic.

Industrial multimedia over factory-floor networks

In this paper we describe a real-time industrial communication network able to support both controlrelated and multimedia traffic. The industrial communication network is based on the PROFIBUS standard, with multimedia capabilities being provided by an adequate integration of TCP/IP protocols into the PROFIBUS stack. From the operational point of view the integration of TCP/IP into PROFIBUS is by itself a challenge, since the master-slave nature of the PROFIBUS MAC makes complex the implementation of the symmetry inherent to IP communications. From the timeliness point of view the challenge is two folded. On one hand the multimedia traffic should not interfere with the timing requirements of the "native" control-related PROFIBUS traffic (typically hard real-time). On the other hand multimedia traffic requires certain levels of quality-of-service to be attained. In this paper we provide a methodology that enables fulfilling the timing requirements for both types of traffic in these real-time industrial LAN. Moreover, we describe suitable algorithms for the scheduling support of concurrent multimedia streams.

Setting target rotation time in PROFIBUS based real-time distributed applications

In this paper, we analyse the ability of Profibus fieldbus to cope with the real-time requirements of a Distributed Computer Control System (DCCS), where messages associated to discrete events must be made available within a maximum bound time. Our methodology is based on the knowledge of real-time traffic characteristics, setting the network parameters in order to cope with timing requirements. Since non-real-time traffic characteristics are usually unknown at the design stage, we consider an operational profile where, constraining non-real-time traffic at the application level, we assure that realtime requirements are met.

Cycle time properties of the PROFIBUS timed-token protocol

A recent trend in distributed computer-controlled systems (DCCS) is to interconnect the distributed computing elements by means of multi-point broadcast networks. Since the network medium is shared between a number of network nodes, access contention exists and must be solved by a medium access control (MAC) protocol. Usually, DCCS impose real-time constraints. In essence, by real-time constraints we mean that traffic must be sent and received within a bounded interval, otherwise a timing fault is said to occur. This motivates the use of communication networks with a MAC protocol that guarantees bounded access and response times to message requests. PROFIBUS is a communication network in which the MAC protocol is based on a simplified version of the timed-token protocol. In this paper we address the cycle time properties of the PROFIBUS MAC protocol, since the knowledge of these properties is of paramount importance for guaranteeing the real-time behaviour of a distributed computer-controlled system which is supported by this type of network.

Supporting real-time distributed computer-controlled systems with multi-hop P-NET networks

Fieldbus communication networks aim to interconnect sensors, actuators and controllers within process control applications. Therefore, they constitute the foundation upon which real-time distributed computer-controlled systems can be implemented. P-NET is a fieldbus communication standard, which uses a virtual token-passing medium-access-control mechanism. In this paper pre-run-time schedulability conditions for supporting real-time traffic with P-NET networks are established. Essentially, formulae to evaluate the upper bound of the end-to-end communication delay in P-NET messages are provided. Using this upper bound, a feasibility test is then provided to check the timing requirements for accessing remote process variables. This paper also shows how P-NET network segmentation can significantly reduce the end-to-end communication delays for messages with stringent timing requirements.

Communication response time in P-NET networks: worst-case analysis considering the actual token utilisation

Fieldbus networks aim at the interconnection of field devices such as sensors, actuators and small controllers. Therefore, they are an effective technology upon which Distributed Computer Controlled Systems (DCCS) can be built. DCCS impose strict timeliness requirements to the communication network. In essence, by timeliness requirements we mean that traffic must be sent and received within a bounded interval, otherwise a timing fault is said to occur. P-NET is a multi-master fieldbus standard based on a virtual token passing scheme. In P-NET each master is allowed to transmit only one message per token visit, which means that in the worst-case the communication response time could be derived considering that the token is fully utilised by all stations. However, such analysis can be proved to be quite pessimistic. In this paper we propose a more sophisticated P-NET timing analysis model, which considers the actual token utilisation by different masters. The major contribution of this model is to provide a less pessimistic, and thus more accurate, analysis for the evaluation of the worst-case communication response time in P-NET fieldbus networks.

Queuing and routing in a hierarchical powerline communication system

Although power-line communication (PLC) is not a new technology, its use to support data communication with timing requirements is still the focus of ongoing research. A new infrastructure intended for communication using power lines from a central location to dispersed nodes using inexpensive devices was presented recently. This new infrastructure uses a two-level hierarchical power-line system, together with an IP-based network. Due to the master-slave behaviour of the PLC medium access, together with the inherent dynamic topology of power-line networks, a mechanism to provide end-to-end communication through the two levels of the power-line system must be provided. In this paper we introduce the architecture of the PLC protocol layer that is being implemented for this end.

INDEPTH: timeliness assessment of ethernet/IP-based systems

The continuous improvement of Ethernet technologies is boosting the eagerness of extending their use to cover factory-floor distributed real time applications. Indeed, it is remarkable the considerable amount of research work that has been devoted to the timing analysis of Ethernet-based technologies in the past few years. It happens, however, that the majority of those works are restricted to the analysis of sub-sets of the overall computing and communication system, thus without addressing timeliness in a holistic fashion. To this end, we address an approach, based on simulation, aiming at extracting temporal properties of commercial-off-the-shelf (COTS) Ethernet-based factory-floor distributed systems. This framework is applied to a specific COTS technology, Ethernet/IP. We reason about the modeling and simulation of Ethernet/IP-based systems, and on the use of statistical analysis techniques to provide useful results on timeliness. The approach is part of a wider framework related to the research project INDEPTH NDustrial-Ethernet ProTocols under Holistic analysis.

Timeliness in COTS factory-floor distributed systems: What role for simulation?

In the past few years, a significant amount of work has been devoted to the timing analysis of Ethernet-based technologies. However, none of these address the problem of timeliness evaluation at a holistic level. This paper describes a research framework embracing this objective. It is advocated that, simulation models can be a powerful tool, not only for timeliness evaluation, but also to enable the introduction of less pessimistic assumptions in an analytical response time approach, which, most often, are afflicted with simplifications leading to pessimistic assumptions and, therefore, delusive results. To this end, we address a few inter-linked research topics with the purpose of setting a framework for developing tools suitable to extract temporal properties of commercial-off-the-shelf (COTS) factory-floor communication systems.