Architectures and design patterns for functional design of logic control and diagnostics in industrial automation

Recently in most of the industrial automation process an ever increasing degree of automation has been observed. This increasing is motivated by the higher requirement of systems with great performance in terms of quality of products/services generated, productivity, efficiency and low costs in the design, realization and maintenance. This trend in the growth of complex automation systems is rapidly spreading over automated manufacturing systems (AMS), where the integration of the mechanical and electronic technology, typical of the Mechatronics, is merging with other technologies such as Informatics and the communication networks. An AMS is a very complex system that can be thought constituted by a set of flexible working stations, one or more transportation systems. To understand how this machine are important in our society let considerate that every day most of us use bottles of water or soda, buy product in box like food or cigarets and so on. Another important consideration from its complexity derive from the fact that the the consortium of machine producers has estimated around 350 types of manufacturing machine. A large number of manufacturing machine industry are presented in Italy and notably packaging machine industry,in particular a great concentration of this kind of industry is located in Bologna area; for this reason the Bologna area is called “packaging valley”. Usually, the various parts of the AMS interact among them in a concurrent and asynchronous way, and coordinate the parts of the machine to obtain a desiderated overall behaviour is an hard task. Often, this is the case in large scale systems, organized in a modular and distributed manner. Even if the success of a modern AMS from a functional and behavioural point of view is still to attribute to the design choices operated in the definition of the mechanical structure and electrical electronic architecture, the system that governs the control of the plant is becoming crucial, because of the large number of duties associated to it. Apart from the activity inherent to the automation of themachine cycles, the supervisory system is called to perform other main functions such as: emulating the behaviour of traditional mechanical members thus allowing a drastic constructive simplification of the machine and a crucial functional flexibility; dynamically adapting the control strategies according to the different productive needs and to the different operational scenarios; obtaining a high quality of the final product through the verification of the correctness of the processing; addressing the operator devoted to themachine to promptly and carefully take the actions devoted to establish or restore the optimal operating conditions; managing in real time information on diagnostics, as a support of the maintenance operations of the machine. The kind of facilities that designers can directly find on themarket, in terms of software component libraries provides in fact an adequate support as regard the implementation of either top-level or bottom-level functionalities, typically pertaining to the domains of user-friendly HMIs, closed-loop regulation and motion control, fieldbus-based interconnection of remote smart devices. What is still lacking is a reference framework comprising a comprehensive set of highly reusable logic control components that, focussing on the cross-cutting functionalities characterizing the automation domain, may help the designers in the process of modelling and structuring their applications according to the specific needs. Historically, the design and verification process for complex automated industrial systems is performed in empirical way, without a clear distinction between functional and technological-implementation concepts and without a systematic method to organically deal with the complete system. Traditionally, in the field of analog and digital control design and verification through formal and simulation tools have been adopted since a long time ago, at least for multivariable and/or nonlinear controllers for complex time-driven dynamics as in the fields of vehicles, aircrafts, robots, electric drives and complex power electronics equipments. Moving to the field of logic control, typical for industrial manufacturing automation, the design and verification process is approached in a completely different way, usually very “unstructured”. No clear distinction between functions and implementations, between functional architectures and technological architectures and platforms is considered. Probably this difference is due to the different “dynamical framework”of logic control with respect to analog/digital control. As a matter of facts, in logic control discrete-events dynamics replace time-driven dynamics; hence most of the formal and mathematical tools of analog/digital control cannot be directly migrated to logic control to enlighten the distinction between functions and implementations. In addition, in the common view of application technicians, logic control design is strictly connected to the adopted implementation technology (relays in the past, software nowadays), leading again to a deep confusion among functional view and technological view. In Industrial automation software engineering, concepts as modularity, encapsulation, composability and reusability are strongly emphasized and profitably realized in the so-calledobject-oriented methodologies. Industrial automation is receiving lately this approach, as testified by some IEC standards IEC 611313, IEC 61499 which have been considered in commercial products only recently. On the other hand, in the scientific and technical literature many contributions have been already proposed to establish a suitable modelling framework for industrial automation. During last years it was possible to note a considerable growth in the exploitation of innovative concepts and technologies from ICT world in industrial automation systems. For what concerns the logic control design, Model Based Design (MBD) is being imported in industrial automation from software engineering field. Another key-point in industrial automated systems is the growth of requirements in terms of availability, reliability and safety for technological systems. In other words, the control system should not only deal with the nominal behaviour, but should also deal with other important duties, such as diagnosis and faults isolations, recovery and safety management. Indeed, together with high performance, in complex systems fault occurrences increase. This is a consequence of the fact that, as it typically occurs in reliable mechatronic systems, in complex systems such as AMS, together with reliable mechanical elements, an increasing number of electronic devices are also present, that are more vulnerable by their own nature. The diagnosis problem and the faults isolation in a generic dynamical system consists in the design of an elaboration unit that, appropriately processing the inputs and outputs of the dynamical system, is also capable of detecting incipient faults on the plant devices, reconfiguring the control system so as to guarantee satisfactory performance. The designer should be able to formally verify the product, certifying that, in its final implementation, it will perform itsrequired function guarantying the desired level of reliability and safety; the next step is that of preventing faults and eventually reconfiguring the control system so that faults are tolerated. On this topic an important improvement to formal verification of logic control, fault diagnosis and fault tolerant control results derive from Discrete Event Systems theory. The aimof this work is to define a design pattern and a control architecture to help the designer of control logic in industrial automated systems. The work starts with a brief discussion on main characteristics and description of industrial automated systems on Chapter 1. In Chapter 2 a survey on the state of the software engineering paradigm applied to industrial automation is discussed. Chapter 3 presentes a architecture for industrial automated systems based on the new concept of Generalized Actuator showing its benefits, while in Chapter 4 this architecture is refined using a novel entity, the Generalized Device in order to have a better reusability and modularity of the control logic. In Chapter 5 a new approach will be present based on Discrete Event Systems for the problemof software formal verification and an active fault tolerant control architecture using online diagnostic. Finally conclusive remarks and some ideas on new directions to explore are given. In Appendix A are briefly reported some concepts and results about Discrete Event Systems which should help the reader in understanding some crucial points in chapter 5; while in Appendix B an overview on the experimental testbed of the Laboratory of Automation of University of Bologna, is reported to validated the approach presented in chapter 3, chapter 4 and chapter 5. In Appendix C some components model used in chapter 5 for formal verification are reported.

Application of selected industrial engineering techniques to wastewater treatment plants,

"EPA-R2-73-176."

Power control in cognitive radios, Internet-of Things (IoT) for factories and industrial automation

Cognitive radio (CR) is fast emerging as a promising technology that can meet the machine-to machine (M2M) communication requirements for spectrum utilization and power control for large number of machines/devices expected to be connected to the Internet-of Things (IoT). Power control in CR as a secondary user can been modelled as a non-cooperative game cost function to quantify and reduce its effects of interference while occupying the same spectrum as primary user without adversely affecting the required quality of service (QoS) in the network. In this paper a power loss exponent that factors in diverse operating environments for IoT is employed in the non-cooperative game cost function to quantify the required power of transmission in the network. The approach would enable various CRs to transmit with lesser power thereby saving battery consumption or increasing the number of secondary users thereby optimizing the network resources efficiently.

Unveiling fieldbus network technology through project-based learning

Fieldbus communications networks are a fundamental part of modern industrial automation technique. This paperwork presents an application of project-based learning (PBL) paradigm to help electrical engineering students grasp the major concepts of fieldbus networks, while attending a one-term long, elective microcontroller course. © 2012 IEEE.

Reliability analysis of transform-based stereo matching techniques, and a new matching constraint

Stereo vision is a method of depth perception, in which depth information is inferred from two (or more) images of a scene, taken from different perspectives. Practical applications for stereo vision include aerial photogrammetry, autonomous vehicle guidance, robotics and industrial automation. The initial motivation behind this work was to produce a stereo vision sensor for mining automation applications. For such applications, the input stereo images would consist of close range scenes of rocks. A fundamental problem faced by matching algorithms is the matching or correspondence problem. This problem involves locating corresponding points or features in two images. For this application, speed, reliability, and the ability to produce a dense depth map are of foremost importance. This work implemented a number of areabased matching algorithms to assess their suitability for this application. Area-based techniques were investigated because of their potential to yield dense depth maps, their amenability to fast hardware implementation, and their suitability to textured scenes such as rocks. In addition, two non-parametric transforms, the rank and census, were also compared. Both the rank and the census transforms were found to result in improved reliability of matching in the presence of radiometric distortion - significant since radiometric distortion is a problem which commonly arises in practice. In addition, they have low computational complexity, making them amenable to fast hardware implementation. Therefore, it was decided that matching algorithms using these transforms would be the subject of the remainder of the thesis. An analytic expression for the process of matching using the rank transform was derived from first principles. This work resulted in a number of important contributions. Firstly, the derivation process resulted in one constraint which must be satisfied for a correct match. This was termed the rank constraint. The theoretical derivation of this constraint is in contrast to the existing matching constraints which have little theoretical basis. Experimental work with actual and contrived stereo pairs has shown that the new constraint is capable of resolving ambiguous matches, thereby improving match reliability. Secondly, a novel matching algorithm incorporating the rank constraint has been proposed. This algorithm was tested using a number of stereo pairs. In all cases, the modified algorithm consistently resulted in an increased proportion of correct matches. Finally, the rank constraint was used to devise a new method for identifying regions of an image where the rank transform, and hence matching, are more susceptible to noise. The rank constraint was also incorporated into a new hybrid matching algorithm, where it was combined a number of other ideas. These included the use of an image pyramid for match prediction, and a method of edge localisation to improve match accuracy in the vicinity of edges. Experimental results obtained from the new algorithm showed that the algorithm is able to remove a large proportion of invalid matches, and improve match accuracy.

A Taxonomy of image matching techniques for stereo vision

Stereo vision is a method of depth perception, in which depth information is inferred from two (or more) images of a scene, taken from different perspectives. Applications of stereo vision include aerial photogrammetry, autonomous vehicle guidance, robotics, industrial automation and stereomicroscopy. A key issue in stereo vision is that of image matching, or identifying corresponding points in a stereo pair. The difference in the positions of corresponding points in image coordinates is termed the parallax or disparity. When the orientation of the two cameras is known, corresponding points may be projected back to find the location of the original object point in world coordinates. Matching techniques are typically categorised according to the nature of the matching primitives they use and the matching strategy they employ. This report provides a detailed taxonomy of image matching techniques, including area based, transform based, feature based, phase based, hybrid, relaxation based, dynamic programming and object space methods. A number of area based matching metrics as well as the rank and census transforms were implemented, in order to investigate their suitability for a real-time stereo sensor for mining automation applications. The requirements of this sensor were speed, robustness, and the ability to produce a dense depth map. The Sum of Absolute Differences matching metric was the least computationally expensive; however, this metric was the most sensitive to radiometric distortion. Metrics such as the Zero Mean Sum of Absolute Differences and Normalised Cross Correlation were the most robust to this type of distortion but introduced additional computational complexity. The rank and census transforms were found to be robust to radiometric distortion, in addition to having low computational complexity. They are therefore prime candidates for a matching algorithm for a stereo sensor for real-time mining applications. A number of issues came to light during this investigation which may merit further work. These include devising a means to evaluate and compare disparity results of different matching algorithms, and finding a method of assigning a level of confidence to a match. Another issue of interest is the possibility of statistically combining the results of different matching algorithms, in order to improve robustness.

Tactile Sensing for Mechatronics: A State of the Art Survey

Lee M.H. and Nicholls H.R., Tactile Sensing for Mechatronics: A State of the Art Survey, Mechatronics, 9, Jan 1999, pp1-31.

Enhanced ethernet switching technology for adaptive hard real-time applications: Tecnologia de comutação ethernet melhorada para aplicações adaptativas e críticas de tempo-real

Os Sistemas Embarcados Distribuídos (SEDs) estão, hoje em dia, muito difundidos em vastas áreas, desde a automação industrial, a automóveis, aviões, até à distribuição de energia e protecção do meio ambiente. Estes sistemas são, essencialmente, caracterizados pela integração distribuída de aplicações embarcadas, autónomas mas cooperantes, explorando potenciais vantagens em termos de modularidade, facilidade de manutenção, custos de instalação, tolerância a falhas, entre outros. Contudo, o ambiente operacional onde se inserem estes tipos de sistemas pode impor restrições temporais rigorosas, exigindo que o sistema de comunicação subjacente consiga transmitir mensagens com garantias temporais. Contudo, os SEDs apresentam uma crescente complexidade, uma vez que integram subsistemas cada vez mais heterogéneos, quer ao nível do tráfego gerado, quer dos seus requisitos temporais. Em particular, estes subsistemas operam de forma esporádica, isto é, suportam mudanças operacionais de acordo com estímulos exteriores. Estes subsistemas também se reconfiguram dinamicamente de acordo com a actualização dos seus requisitos e, ainda, têm lidar com um número variável de solicitações de outros subsistemas. Assim sendo, o nível de utilização de recursos pode variar e, desta forma, as políticas de alocação estática tornam-se muito ineficientes. Consequentemente, é necessário um sistema de comunicação capaz de suportar com eficácia reconfigurações e adaptações dinâmicas. A tecnologia Ethernet comutada tem vindo a emergir como uma solução sólida para fornecer comunicações de tempo-real no âmbito dos SEDs, como comprovado pelo número de protocolos de tempo-real que foram desenvolvidos na última década. No entanto, nenhum dos protocolos existentes reúne as características necessárias para fornecer uma eficiente utilização da largura de banda e, simultaneamente, para respeitar os requisitos impostos pelos SEDs. Nomeadamente, a capacidade para controlar e policiar tráfego de forma robusta, conjugada com suporte à reconfiguração e adaptação dinâmica, não comprometendo as garantias de tempo-real. Esta dissertação defende a tese de que, pelo melhoramento dos comutadores Ethernet para disponibilizarem mecanismos de reconfiguração e isolamento de tráfego, é possível suportar aplicações de tempo-real críticas, que são adaptáveis ao ambiente onde estão inseridas.Em particular, é mostrado que as técnicas de projecto, baseadas em componentes e apoiadas no escalonamento hierárquico de servidores de tráfego, podem ser integradas nos comutadores Ethernet para alcançar as propriedades desejadas. Como suporte, é fornecida, também, uma solução para instanciar uma hierarquia reconfigurável de servidores de tráfego dentro do comutador, bem como a análise adequada ao modelo de escalonamento. Esta última fornece um limite superior para o tempo de resposta que os pacotes podem sofrer dentro dos servidores de tráfego, com base unicamente no conhecimento de um dado servidor e na hierarquia actual, isto é, sem o conhecimento das especifidades do tráfego dentro dos outros servidores. Finalmente, no âmbito do projecto HaRTES foi construído um protótipo do comutador Ethernet, o qual é baseado no paradigma “Flexible Time-Triggered”, que permite uma junção flexível de uma fase síncrona para o tráfego controlado pelo comutador e uma fase assíncrona que implementa a estrutura hierárquica de servidores referidos anteriormente. Além disso, as várias experiências práticas realizadas permitiram validar as propriedades desejadas e, consequentemente, a tese que fundamenta esta dissertação.

Group Sequential Communication (GSC): Especificação e Análise de Desempenho de umMecanismo de Comunicação de Tempo Real Compatível ao Padrão IEEE 802.11/11e Aplicado à Automação Industrial

This thesis proposes the specification and performance analysis of a real-time communication mechanism for IEEE 802.11/11e standard. This approach is called Group Sequential Communication (GSC). The GSC has a better performance for dealing with small data packets when compared to the HCCA mechanism by adopting a decentralized medium access control using a publish/subscribe communication scheme. The main objective of the thesis is the HCCA overhead reduction of the Polling, ACK and QoS Null frames exchanged between the Hybrid Coordinator and the polled stations. The GSC eliminates the polling scheme used by HCCA scheduling algorithm by using a Virtual Token Passing procedure among members of the real-time group to whom a high-priority and sequential access to communication medium is granted. In order to improve the reliability of the mechanism proposed into a noisy channel, it is presented an error recovery scheme called second chance algorithm. This scheme is based on block acknowledgment strategy where there is a possibility of retransmitting when missing real-time messages. Thus, the GSC mechanism maintains the real-time traffic across many IEEE 802.11/11e devices, optimized bandwidth usage and minimal delay variation for data packets in the wireless network. For validation purpose of the communication scheme, the GSC and HCCA mechanisms have been implemented in network simulation software developed in C/C++ and their performance results were compared. The experiments show the efficiency of the GSC mechanism, especially in industrial communication scenarios.

Implementação de uma plataforma HW/SW para automação industrial, utilizando hardware reconfigurável com processador NIOS II em conformidade com o padrão IEEE 1451

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

O uso do marketing B2B em pequenas e médias empresas: um estudo exploratório no setor de automação industrial do Vale do Paraíba paulista

Pós-graduação em Engenharia Mecânica - FEG

Mitigação de falhas críticas em sistemas produtivos.

O cenário competitivo e globalizado em que as empresas estão inseridas, sobretudo a partir do século XXI, associados a ciclos de vida cada vez menores dos produtos, rigorosos requisitos de qualidade, além de políticas de preservação do meio ambiente, com redução de consumo energético e de recursos hídricos, somadas às exigências legais de melhores condições de trabalho, resultaram em uma quebra de paradigma nos processos produtivos até então concebidos. Como solução a este novo cenário produtivo pode-se citar o extenso uso da automação industrial, fato que resultou em sistemas cada vez mais complexos, tanto do ponto de vista estrutural, em função do elevado número de componentes, quanto da complexidade dos sistemas de controle. A previsibilidade de todos os estados possíveis do sistema torna-se praticamente impossível. Dentre os estados possíveis pode-se citar os estados de falha que, dependendo da severidade do efeito associado à sua ocorrência, podem resultar em sérios danos para o homem, o meio ambiente e às próprias instalações, caso não sejam corretamente diagnosticados e tratados. Fatos recentes de catástrofes relacionadas à sistemas produtivos revelam a necessidade de se implementar medidas para prevenir e para mitigar os efeitos da ocorrência de falhas, com o objetivo de se evitar a ocorrência de catástrofes. De acordo com especialistas, os Sistemas Instrumentados de Segurança SIS, referenciados em normas como a IEC 61508 e IEC 61511, são uma solução para este tipo de problema. Trabalhos publicados tratam de métodos para a implementação de camadas SIS de prevenção, porém com escassez de trabalhos para camadas SIS de mitigação. Em função do desconhecimento da dinâmica do sistema em estado de falha, técnicas tradicionais de modelagem tornam-se inviáveis. Neste caso, o uso de inteligência artificial, como por exemplo a lógica fuzzy, pode se tornar uma solução para o desenvolvimento do algoritmo de controle, associadas a ferramentas de edição, modelagem e geração dos códigos de controle. A proposta deste trabalho é apresentar uma sistemática para a implementação de um sistema de controle para a mitigação de falhas críticas em sistemas produtivos, com referência às normas IEC 61508/61511, com ação antecipativa à ocorrência de catástrofes.

Network protocols and predictive control strategies for distributed real-time control applications

A trend in design and implementation of modern industrial automation systems is to integrate computing, communication and control into a unified framework at different levels of machine/factory operations and information processing. These distributed control systems are referred to as networked control systems (NCSs). They are composed of sensors, actuators, and controllers interconnected over communication networks. As most of communication networks are not designed for NCS applications, the communication requirements of NCSs may be not satisfied. For example, traditional control systems require the data to be accurate, timely and lossless. However, because of random transmission delays and packet losses, the control performance of a control system may be badly deteriorated, and the control system rendered unstable. The main challenge of NCS design is to both maintain and improve stable control performance of an NCS. To achieve this, communication and control methodologies have to be designed. In recent decades, Ethernet and 802.11 networks have been introduced in control networks and have even replaced traditional fieldbus productions in some real-time control applications, because of their high bandwidth and good interoperability. As Ethernet and 802.11 networks are not designed for distributed control applications, two aspects of NCS research need to be addressed to make these communication networks suitable for control systems in industrial environments. From the perspective of networking, communication protocols need to be designed to satisfy communication requirements for NCSs such as real-time communication and high-precision clock consistency requirements. From the perspective of control, methods to compensate for network-induced delays and packet losses are important for NCS design. To make Ethernet-based and 802.11 networks suitable for distributed control applications, this thesis develops a high-precision relative clock synchronisation protocol and an analytical model for analysing the real-time performance of 802.11 networks, and designs a new predictive compensation method. Firstly, a hybrid NCS simulation environment based on the NS-2 simulator is designed and implemented. Secondly, a high-precision relative clock synchronization protocol is designed and implemented. Thirdly, transmission delays in 802.11 networks for soft-real-time control applications are modeled by use of a Markov chain model in which real-time Quality-of- Service parameters are analysed under a periodic traffic pattern. By using a Markov chain model, we can accurately model the tradeoff between real-time performance and throughput performance. Furthermore, a cross-layer optimisation scheme, featuring application-layer flow rate adaptation, is designed to achieve the tradeoff between certain real-time and throughput performance characteristics in a typical NCS scenario with wireless local area network. Fourthly, as a co-design approach for both a network and a controller, a new predictive compensation method for variable delay and packet loss in NCSs is designed, where simultaneous end-to-end delays and packet losses during packet transmissions from sensors to actuators is tackled. The effectiveness of the proposed predictive compensation approach is demonstrated using our hybrid NCS simulation environment.

A process-oriented approach to supporting Off-site Manufacture in construction projects

It is well-known that the use of off-site manufacture (OSM) techniques can assist in timely completion of a construction project though the utilisation of such techniques may have other disadvantages. Currently, OSM uptake within the Australian construction industry is limited. To successfully incorporate OSM practices within a construction project, it is crucial to understand the impact of OSM adoption on the processes used during a construction project. This paper presents how a systematic process-oriented approach may be able to support OSM utilisation within a construction project. Process modelling, analysis and automation techniques which are well-known within the Business Process Management (BPM) discipline have been applied to develop a collection of construction process models that represent the end-to-end generic construction value chain. The construction value chain enables researchers to identify key activities, resources, data, and stakeholders involved in construction processes in each defined construction phase. The collection of construction process models is then used as a basis for identification of potential OSM intervention points in collaboration with domain experts from the Australian construction industry. This ensures that the resulting changes reflect the needs of various stakeholders within the construction industry and have relevance in practice. Based on the input from the domain experts, these process models are further refined and operational requirements are taken into account to develop a prototype process automation (workflow) system that can support and coordinate OSM-related process activities. The resulting workflow system also has the potential to integrate with other IT solutions used within the construction industry (e.g., BIM, Acconex). As such, the paper illustrates the role that process-oriented thinking can play in assisting OSM adoption within the industry.