Architectures for Manufacturing

Richard A. Wysk

IE551 - Computer Control of Manufacturing Systems

Agenda

• Types of manufacturing architectures

• Architectural linkages• Integration/hooks

What is an Architecture?–“a style or method of design and construction”–“a design or orderly arrangement perceived by man”

Why are architectures important?Relevant for CIM control

Introduction

Types of Architectures

Different architectures in a manufacturing

facility Physical Logical Organizational

The Physical Layout

• Adjacency• Floor space utilization• Accessibility• Flexibility

Integrated CIM Cell

Material Transport Cart

Material Transport Cart

Material Transport Cart

KardexAS/RS

IBM 7535

Bridge

port

CNC Mill

Fanuc A0Cartrac Unit Conveyor

Transport System

Storage Workstation

Prismatic Machining Workstation

Rotational Machining Workstation

Horizon VVertical Mill

IBM 7545

Material Transport Cart

Assembly Workstation

Part Inverter

BufferFaunc M1-L

DaewooPumaTurningCenter

Unit D

Functional ArchitectureHow tasks relate to each otherSalesMarketingOrder entryProduction controlProcess planningEtc.

Communication Architecture• Linkages between entities that

allow forthe transmission of information

• Physical layer• Protocols and packeting of

information• See Chapter 6 of Chang et al

Information System Architecture• Data repositiories• Access method (DMA, TCP/IP, etc.)• Assess protocol (SQL, ODBC, fixed

read, etc.)• Ownership/privilege

DHC

DHS

DHC

DHC

DHC

DHC

DHS - Data Handler ServerDHC - Data Handler Client

ControllerDatabase

......

Example

Control Architecture• Considers all other architectures• Organization architecture

Responsibility Ownership Functions

A Controller

Planning

Scheduling

Execution

Data Handler Equipment process plan (e.g. CAD file)

Equipment Controller

Convert

Machine Controller

Physical Machine

Device specific data(e.g. NC file, CL data, etc.)

Individual spindle/jointactivation commands

An Equipment Controller

Equip Equip Equip Equip Equip Equip

Wkstn WkstnWkstnResource Manager

Shop

A Collection of Controllers

Control Architecture

Hierarchical control (Master/Slave) Decomposition of functions into a tree

structure Logical layers of control

Heterarchical control Democracy at work Cooperative control

Several specifications of both ICAM 7 layer hierarchy NIST hierarchy

Planning Scheduling Execution Equip Operations-level

planning (e.g. tool path planning)

Determining the start/finish times for the individual tasks. Determining the sequence of part processing when multiple parts are allowed.

Interacting with the machine controller to initiate and monitor part processing.

Wkstn Determining the part routes through the workstation (e.g. selection of processing equipment). Includes replanning in response to machine breakdowns.

Determining the start/fininsh timnes for each part on each processing machine in the workstation

Interacting with the equipment level controllers to assign and remove parts and to syunchronize the activites of the devices (e.g. as required when using a robot to load a part on a machine tool).

Shop Determining the part routes through the shop. Splitting part orders into batches to match material transport and workstation capacity constraints.

Determining the start/finish times for part batches at each workstation.

Interacting with the workstation controllers and the Resource Manager to deliver/pickup parts.

What do we need to know?

• Computer control• Communications• Functional control• Information access and

processing

Where we go from here?

• Overview of architectures • Functional architectures Functional architectures • Information architectures Information architectures • Communication architectures Communication architectures • RapidCIM RapidCIM • Simulation-based Control Simulation-based Control • Holonic ManufacturingHolonic Manufacturing

Resources• Hoberecht, W. C., Smith, J. S., and Joshi, S. B., “Architectures for factory

control”, AUTOFACT, Conference Proceedings, AUTOFACT'92 Conference Proceedings, Sep 10-12 1992, Detroit, MI, USA., Sponsored by: Society of Manufacturing Engineers; Computer and Automated Systems Association of SME Publ by SME, Dearborn, MI, USA, p 13-27-39.

• Joshi, S. B., Mettala, E. G., Smith J. S., and Wysk, R. A., “Formal models for control of flexible manufacturing cells: physical and system model”, IEEE Transactions on Robotics and Automation, v11, n4, Aug, 1995 IEEE, Piscataway, NJ, USA, p 558-570.

• Smith, J. S., Hoberecht, W. C., and Joshi, S. B. “Shop-floor control architecture for computer-integrated manufacturing” IIE Transactions (Institute of Industrial Engineers), v28, n10, Oct, 1996 Chapman & Hall Ltd, London, U.K., p 783-794.