Modeling extended Petri nets compatible with GHENeSys IEC61131 for industrial automation

Petri net (PN) modeling is one of the most used formal methods in the automation applications field, together with programmable logic controllers (PLCs). Therefore, the creation of a modeling methodology for PNs compatible with the IEC61131 standard is a necessity of automation specialists. Different works dealing with this subject have been carried out; they are presented in the first part of this paper [Frey (2000a, 2000b); Peng and Zhou (IEEE Trans Syst Man Cybern, Part C Appl Rev 34(4):523-531, 2004); Uzam and Jones (Int J Adv Manuf Technol 14(10):716-728, 1998)], but they do not present a completely compatible methodology with this standard. At the same time, they do not maintain the simplicity required for such applications, nor the use of all-graphical and all-mathematical ordinary Petri net (OPN) tools to facilitate model verification and validation. The proposal presented here completes these requirements. Educational applications at the USP and UEA (Brazil) and the UO (Cuba), as well as industrial applications in Brazil and Cuba, have already been carried out with good results.

An internet remote laboratory to teach industrial automation

This paper presents the new internet remote laboratory (IRL), constructed at Mechanical Engineering Department (MED), Instituto Superior de Engenharia de Lisboa (ISEL), to teach Industrial Automation, namely electropneumatic cycles. The aim of this work was the development and implementation of a remote laboratory that was simple and effective from the user point of view, allowing access to all its functionalities through a web browser without having to install any other program and giving access to all the features that the students can find at the physical laboratory. With this goal in mind, it has been implemented a simple architecture with the new programmable logic controller (PLC) SIEMENS S7-1200, and with the aid of several free programs, programming technologies such as JavaScript, PHP and databases, it was possible to have a remote laboratory, with a simple interface, to teach industrial automation students.

Service-oriented architecture for device lifecycle support in industrial automation

Dissertação para obtenção do Grau de Doutor em Engenharia Electrotécnica e de Computadores Especialidade: Robótica e Manufactura Integrada

Three essays on major trends in a slow clockspeed industry : the case of industrial automation

The motivation for this research initiated from the abrupt rise and fall of minicomputers which were initially used both for industrial automation and business applications due to their significantly lower cost than their predecessors, the mainframes. Later industrial automation developed its own vertically integrated hardware and software to address the application needs of uninterrupted operations, real-time control and resilience to harsh environmental conditions. This has led to the creation of an independent industry, namely industrial automation used in PLC, DCS, SCADA and robot control systems. This industry employs today over 200'000 people in a profitable slow clockspeed context in contrast to the two mainstream computing industries of information technology (IT) focused on business applications and telecommunications focused on communications networks and hand-held devices. Already in 1990s it was foreseen that IT and communication would merge into one Information and communication industry (ICT). The fundamental question of the thesis is: Could industrial automation leverage a common technology platform with the newly formed ICT industry? Computer systems dominated by complex instruction set computers (CISC) were challenged during 1990s with higher performance reduced instruction set computers (RISC). RISC started to evolve parallel to the constant advancement of Moore's law. These developments created the high performance and low energy consumption System-on-Chip architecture (SoC). Unlike to the CISC processors RISC processor architecture is a separate industry from the RISC chip manufacturing industry. It also has several hardware independent software platforms consisting of integrated operating system, development environment, user interface and application market which enables customers to have more choices due to hardware independent real time capable software applications. An architecture disruption merged and the smartphone and tablet market were formed with new rules and new key players in the ICT industry. Today there are more RISC computer systems running Linux (or other Unix variants) than any other computer system. The astonishing rise of SoC based technologies and related software platforms in smartphones created in unit terms the largest installed base ever seen in the history of computers and is now being further extended by tablets. An underlying additional element of this transition is the increasing role of open source technologies both in software and hardware. This has driven the microprocessor based personal computer industry with few dominating closed operating system platforms into a steep decline. A significant factor in this process has been the separation of processor architecture and processor chip production and operating systems and application development platforms merger into integrated software platforms with proprietary application markets. Furthermore the pay-by-click marketing has changed the way applications development is compensated: Three essays on major trends in a slow clockspeed industry: The case of industrial automation 2014 freeware, ad based or licensed - all at a lower price and used by a wider customer base than ever before. Moreover, the concept of software maintenance contract is very remote in the app world. However, as a slow clockspeed industry, industrial automation has remained intact during the disruptions based on SoC and related software platforms in the ICT industries. Industrial automation incumbents continue to supply systems based on vertically integrated systems consisting of proprietary software and proprietary mainly microprocessor based hardware. They enjoy admirable profitability levels on a very narrow customer base due to strong technology-enabled customer lock-in and customers' high risk leverage as their production is dependent on fault-free operation of the industrial automation systems. When will this balance of power be disrupted? The thesis suggests how industrial automation could join the mainstream ICT industry and create an information, communication and automation (ICAT) industry. Lately the Internet of Things (loT) and weightless networks, a new standard leveraging frequency channels earlier occupied by TV broadcasting, have gradually started to change the rigid world of Machine to Machine (M2M) interaction. It is foreseeable that enough momentum will be created that the industrial automation market will in due course face an architecture disruption empowered by these new trends. This thesis examines the current state of industrial automation subject to the competition between the incumbents firstly through a research on cost competitiveness efforts in captive outsourcing of engineering, research and development and secondly researching process re- engineering in the case of complex system global software support. Thirdly we investigate the industry actors', namely customers, incumbents and newcomers, views on the future direction of industrial automation and conclude with our assessments of the possible routes industrial automation could advance taking into account the looming rise of the Internet of Things (loT) and weightless networks. Industrial automation is an industry dominated by a handful of global players each of them focusing on maintaining their own proprietary solutions. The rise of de facto standards like IBM PC, Unix and Linux and SoC leveraged by IBM, Compaq, Dell, HP, ARM, Apple, Google, Samsung and others have created new markets of personal computers, smartphone and tablets and will eventually also impact industrial automation through game changing commoditization and related control point and business model changes. This trend will inevitably continue, but the transition to a commoditized industrial automation will not happen in the near future.

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.

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.

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

Development of a Robotic Wires Storage System for Switchgear Manufacturing Automation

Considering the great development of robotics in industrial automation, the Remodel project aims to reproduce, through the use of Cobots, the wiring activity typical of a human operator and to realize an autonomous storage work. My researches focused on this second topic. In this paper, we will see how to realize a gripper compatible with an Omron TM5X-900, able to perform a pick and place of different types of cables, but also how to compute possible trajectories. In particular, what I needed, was a trajectory going from the Komax, the cables production machine, to a Warehouse taking into account the possible entangles of cables with the robot during its motion. The last part has been dedicated to the synchronization between robot and main machine work.

Axis control optimization: autotuning techniques and frequency response analysis of industrial mechatronic systems

In the field of industrial automation, there is an increasing need to use optimal control systems that have low tracking errors and low power and energy consumption. The motors we are dealing with are mainly Permanent Magnet Synchronous Motors (PMSMs), controlled by 3 different types of controllers: a position controller, a speed controller, and a current controller. In this thesis, therefore, we are going to act on the gains of the first two controllers by going to find, through the TwinCAT 3 software, what might be the best set of parameters. To do this, starting with the default parameters recommended by TwinCAT, two main methods were used and then compared: the method of Ziegler and Nichols, which is a tabular method, and advanced tuning, an auto-tuning software method of TwinCAT. Therefore, in order to analyse which set of parameters was the best,several experiments were performed for each case, using the Motion Control Function Blocks. Moreover, some machines, such as large robotic arms, have vibration problems. To analyse them in detail, it was necessary to use the Bode Plot tool, which, through Bode plots, highlights in which frequencies there are resonance and anti-resonance peaks. This tool also makes it easier to figure out which and where to apply filters to improve control.

Influence of the technological innovation degree on knowledge creation: Evidence from a Brazilian firm

The aim of this paper is to analyze the process of knowledge creation when developing high technology products in projects having various innovation degrees. The main contribution to the literature is the systematization of an approach to analyze knowledge creation during the product innovation process. Three innovation projects developed by a company specialized in industrial automation systems were investigated using case studies. The knowledge creation processes, which took place in these three projects, were analyzed comparatively. As a distinctive result of this paper, the main features of the knowledge creation processes influenced by a degree of technological innovation are identified.

Projecto dum laboratório remoto para automação de processos industriais

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Cooperative framework for open real-time systems

Actualmente, os sistemas embebidos estão presentes em toda a parte. Embora grande parte da população que os utiliza não tenha a noção da sua presença, na realidade, se repentinamente estes sistemas deixassem de existir, a sociedade iria sentir a sua falta. A sua utilização massiva deve-se ao facto de estarem practicamente incorporados em quase os todos dispositivos electrónicos de consumo, telecomunicações, automação industrial e automóvel. Influenciada por este crescimento, a comunidade científica foi confrontada com novos problemas distribuídos por vários domínios científicos, dos quais são destacados a gestão da qualidade de serviço e gestão de recursos - domínio encarregue de resolver problemas relacionados com a alocação óptima de recursos físicos, tais como rede, memória e CPU. Existe na literatura um vasto conjunto de modelos que propõem soluções para vários problemas apresentados no contexto destes domínios científicos. No entanto, não é possível encontrar modelos que lidem com a gestão de recursos em ambientes de execução cooperativos e abertos com restrições temporais utilizando coligações entre diferentes nós, de forma a satisfazer os requisitos não funcionais das aplicações. Devido ao facto de estes sistemas serem dinâmicos por natureza, apresentam a característica de não ser possível conhecer, a priori, a quantidade de recursos necessários que uma aplicação irá requerer do sistema no qual irá ser executada. Este conhecimento só é adquirido aquando da execução da aplicação. De modo a garantir uma gestão eficiente dos recursos disponíveis, em sistemas que apresentam um grande dinamismo na execução de tarefas com e sem restrições temporais, é necessário garantir dois aspectos fundamentais. O primeiro está relacionado com a obtenção de garantias na execução de tarefas de tempo-real. Estas devem sempre ser executadas dentro da janela temporal requirida. O segundo aspecto refere a necessidade de garantir que todos os recursos necessários à execução das tarefas são fornecidos, com o objectivo de manter os níveis de performance quer das aplicações, quer do próprio sistema. Tendo em conta os dois aspectos acima mencionados, o projecto CooperatES foi especificado com o objectivo de permitir a dispositivos com poucos recursos uma execução colectiva de serviços com os seus vizinhos, de modo a cumprir com as complexas restrições de qualidade de serviço impostas pelos utilizadores ou pelas aplicações. Decorrendo no contexto do projecto CooperatES, o trabalho resultante desta tese tem como principal objectivo avaliar a practicabilidade dos conceitos principais propostos no âmbito do projecto. O trabalho em causa implicou a escolha e análise de uma plataforma, a análise de requisitos, a implementação e avaliação de uma framework que permite a execução cooperativa de aplicações e serviços que apresentem requisitos de qualidade de serviço. Do trabalho desenvolvido resultaram as seguintes contribuições: Análise das plataformas de código aberto que possam ser utilizadas na implementação dos conceitos relacionados com o projecto CooperatES; Critérios que influenciaram a escolha da plataforma Android e um estudo focado na análise da plataforma sob uma perspectiva de sistemas de tempo-real; Experiências na implementação dos conceitos do projecto na plataforma Android; Avaliação da practicabilidade dos conceitos propostos no projecto CooperatES; Proposta de extensões que permitam incorporar características de sistemas de tempo real abertos na plataforma Android.