NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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The University of Michigan, Ann Arbor

Engineering Research Center for

Reconfigurable Manufacturing Systems

Virtual Fusion: The Complete Integration of Simulated andActual

William Harrison, Graduate StudentJames Moyne, Associate Research Scientist

Dawn Tilbury, Professor

January 14, 2008

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Demonstration

• Run the Reconfigurable Factory Testbed with nosimulated parts

• Replace an entire cell

• Add a cell to the existing infrastructure

• Monitoring

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Inefficient Robot Throughput Low

Cell and Component Swapping in the RFT

Part

Motoman DA20

• 20kg payload/arm

• 13 dof

• “Jigless” operation

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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DEMO: Robot Swapping in the RFT

System Level Controller

CNC

CNC robot

Cell 2

Controller

Conveyor

Conveyor

Controller

CNC

CNCrobot

Cell 1

Controller

Supply Cellcontroller

Gantry

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Supply Cell : Adding a New Cell

• Replace existing manualpart loading station withnew automated system– Example: Overhead gantry

setup

– Simulating the hardwareand the PLC software

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Conveyor

CNC

CNC

CNC

CNC CNC

CNC

Hybrid Process Simulation: Normal Process

CNC

Conveyor

CNC

CNC

Hybrid Process Simulation: Hardwired SimulationHybrid Process Simulation: Hybrid ModeHybrid Process Simulation Extension: Monitoring

CNC

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Cyber-Physical System Integration

• Large amounts ofavailable datanecessitates state of theart interface– Desktop

– 3D Geowall

• Wide Scale Monitoring– In Plant (game engine)

– World Wide (2nd Life)

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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END

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Presentation Outline

• Problem

• Task and Purpose

• Virtual Fusion and Hybrid Process Simulation• Objectives, Deliverables, and Benefits• Application of Hybrid Process Simulation Methodology• Simulation and Modeling• Reality Science• Future Plans• Demo

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Problem: Cost (Ramp Up Time and Change OverTime can always be better)

• Simulation models are sometimes inaccurate

• Expensive to develop

• Centralized in one program and one simulationcompany

• Simulation models go unused after planning

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Task and Purpose

• Task: Reduce Cost by decreasing ramp up andchange over time

– Finding better ways to integrate simulation into thedevelopment process and throughout the product lifecycle

• Purpose of Presentation

– Show the technical developments on the ReconfigurableFactory Testbed

– Briefly introduce intellectual contributions thus far

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering # 12

Virtual Fusion: The Complete Integration of Simulated and Actual-Ongoing (Fall 06) ; Core Project; 1 Student; GM Partner

• Objectives

– Develop HILS methodology

for logic control verification

and validation

– Pre-launch validation,

online monitoring and

operator training

• Key Deliverables

– HILS tools and logic validation survey (CASE 2007)

– HILS implementation on ERC-RFT

– Methodology on use of HILS for logic validation

– Solution for HILS use in monitoring and operator training

• Benefits to Industry– Understand state-of-the-art of HILS in auto manufacturing

– Reduce launch time and downtime due to unanticipated behavior

– Provide platform for testing difficult-to-simulate components

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Inefficient Robot Throughput Low

June 2008 Demo: Cell Swapping in the RFT

Part

Motoman DA20

• 20kg payload/arm

• 13 dof

• “Jigless” operation

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

# 14

Supply Cell : Adding a New Cell

• Replace existing manualpart loading station withnew automated system– Example: Overhead gantry

setup

– Simulating the hardwareand the PLC software

• Current status: VirtualCell is completed andintegration is beingtested

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Fanuc Roboguide Integration

• Leverage Fanuc’s existing

simulation software for

system validation

• Roboguide: Fanuc’s robot

simulation software

– Same interface as real robot

– Execute actual program and

confirm motion path and logic

– Highly accurate simulation of

movement and application

commands

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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• Virtual world reflects

real time “ground truth”

of the plant floor

• Improved information

visualization leads to

better understanding of

system operation, rapid

fault diagnosis and

reduced downtime

Monitoring System Real Time Data

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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Milestones and Future Plans

June 2008

Nov 2009

Dec

2008

May 2009

• Motoman Cell Level Swap

• Robot Emulator Validation

• Supply Cell Addition

• Fanuc Low-Level Simulation Integration

• Methodology for Validation by Swapping

• Methodology for Evaluating System Fidelity

• Monitoring System Implementation on RFT

February 2007

Dec

2008

January 2009