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A Digital Twin Platform for service-based Testing and Optimization

Procedia CIRP 2024年 126卷 260-265页

作者： Shengjian Chen Michael Neubauer Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Seidenstr. 36 70174 Stuttgart Germany

The use of digital twins enables the trend toward a flexible and dynamic production system. As an aspect of digital twins, virtual commissioning models are used to test machines in the engineering phase, before they are even built. These models, however, are no longer used after the engineering phase. In this paper, a concept is presented, for utilizing these models during the production phase in order to optimize the production process. In addition, simple geometrical faults can be detected in the virtual commissioning model and optimized before the control program of the product is deployed on the real machine.

关键词： digital twin platform simulation virtual commissioning software-defined manufacturing

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Semantic Integration and Interdisciplinary Collaboration in Production Planning: A Graph-Based Approach for Enhanced Data Consistency 57

Semantic Integration and Interdisciplinary Collaboration in ...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Dausch, Valesko Lentes, Joachim Riedel, Oliver Kreimeyer, Matthias Institute for Engineering Design and Industrial Design University of Stuttgart Pfaffenwaldring 9 StuttgartDE-70569 Germany Fraunhofer Institute for Industrial Engineering Nobelstrasse 12 StuttgartDE-70569 Germany Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstrasse 36 StuttgartDE-70174 Germany

Based on increasing individualization, shorter innovation cycles and integrating services into products complexity in the development of products and production processes increases. In combination with digitalization, this results in an increased need for interdisciplinary work. A high level of data consistency is required to cope with the resulting diverse and complex data structures, leading to the need for a consistent data model that orchestrates information flows. PLM-systems fall short in their ambition of reaching an overarching data management across the product lifecycle. This results in a lot of administrative work in planning instead of value-adding as well as in inconsistencies and incomplete change processes. To improve interdisciplinary collaboration in production planning, goal of this work is to develop a method leading to a comprehensive data model and to show it's applicability by means of a case study. The steps of the research performed follow the typical circle of action research: diagnosis, planning, action, evaluation, and reflection. The data model resulting of the application of the method uses semantics to make relationships understandable for both humans and machines. This is necessary for downstream automation and the use of artificial intelligence. The three essential steps of the method are, firstly, an as-is modeling of the processes of interest. Then, the process models are used to evaluate the consistency and efficiency of the planning processes. The method is completed by a guideline for setting up the data model. The proposed approach aims to improve efficiency and quality in assembly planning processes, resulting in its importance for industrial companies. © 2024 The Authors.

关键词： Data consistency

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Edge-Cloud Automation of Manufacturing machines: Analysis of Potential Designs and their Impact on the machine Performance 19

Edge-Cloud Automation of Manufacturing Machines: Analysis of...

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19th IEEE International Conference on Automation Science and engineering, CASE 2023

作者： Giani, Marco Tasci, Timur Wiener, Patrick Verl, Alexander Robert Bosch GmbH Robert-Bosch-Campus 1 Renningen71272 Germany The Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstrae 36 Stuttgart70174 Germany

ISBN: (纸本)9798350320695

The migration of industrial automation systems to an edge-cloud hosted on factory premises can reduce the operation costs of a manufacturing line and increase its flexibility thanks to computation scalability and use of cloud-native operation concepts. One limiting factor in the realization of edge-cloud automation systems (ECASs) lies in its operation mode over the network. This may result in tangible delays between the industrial process and the edge-cloud. This paper analyzes how the network delay affects the process performance of an industrial machine on the base of the real-time requirements of the control functions hosted in the edge-cloud. For this purpose, two potential scenarios for the migration of the control system of a real machine to the edge-cloud are implemented. Each scenario features the offloading of more real-time critical control functions to the edge-cloud, which is then tested under increasing load on the network. The study derives classes of automation functions according to the real-time requirements of a potential offloading to the edge-cloud. Furthermore, it shows how complementary designs of an ECAS can affect the performance of the automated systems. In this sense, the results reveal that firm real-time functions can be offloaded to the edge-cloud without any significant loss of performance even if non-real-time networking components are used. On the base of these results, potentials applications domains of ECASs are discussed prospectively and future work is proposed. © 2023 IEEE.

关键词： Automation

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Offline and Online Energy Simulation using Virtual Commissioning Models with Extended Dynamical Behavior

Offline and Online Energy Simulation using Virtual Commissio...

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2025 IEEE/SICE International Symposium on System Integration, SII 2025

作者： Deubert, Darius Pfeifer, Denis Scheifele, Christian Fehr, Jorg Verl, Alexander Bosch Rexroth AG Lohr am Main97816 Germany Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart70174 Germany ISG Industrielle Steuerungstechnik GmbH Stuttgart70563 Germany Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart70174 Germany

ISBN: (纸本)9798331531614

Considering energy consumption and dynamical behavior within the simulation of manufacturing systems emerges as an important objective for their development, commissioning, and operation. Currently, these aspects are often neglected in many fields including virtual commissioning. This work presents an approach to extend highly detailed virtual commissioning models of components from industrial automation by dynamics models for the calculation of energy consumption in an offline simulation and for reuse in an online simulation. To validate the presented approach, an exemplary offline virtual commissioning simulation of a pick-and-place robot application is implemented and subsequently transferred to an online simulation. The validation shows a good accuracy of the simulated energy consumption, enabling virtual commissioning engineers to analyze and optimize energy consumption already in the design phase of manufacturing systems. Additionally, the dynamical behavior was well reflected in the online simulation, contributing to the capability of simulation in the operation phase. © 2025 IEEE.

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Enhanced control Structure for Servo Drives with Adaptive PWM

Enhanced Control Structure for Servo Drives with Adaptive PW...

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International Conference on Power Electronic Drives

作者： Manuel Weiss Florian Frick Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798350372472

ISBN: (纸本)9798350372489

The PWM switching frequency significantly impacts the performance and power dissipation of electrical servo drives. In many fields of application, such as industrial automation, static PWM frequencies are typically used. The novel adaptive PWM approach dynamically adjusts the PWM frequency according to process requirements of manufacturing processes. By adapting the PWM frequency, switching losses and the overall energy consumption of servo drives can be reduced. Changing the PWM frequency at runtime requires enhancements to the control structure for dynamic parameter adjustments and a stable operation of the controllers. To validate the enhanced control structure, an experimental evaluation of the performance at different, dynamically changing PWM frequencies is presented. It is shown that the controller operates with the expected behavior at different frequencies but that there are disturbances at the moment of adjusting the PWM frequency. Non-linearities are identified as a major source, including those caused by IGBT-deadtimes. A simple compensation mechanism is integrated in the enhanced control structure as a proof-of-concept, resulting in an almost complete cancelation of disturbances at the moment of adjusting the PWM frequency.

关键词： Adaptive systems Runtime Manufacturing processes Switching frequency Switching loss Pulse width modulation Power electronics Power dissipation Servomotors Frequency control

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Software-Defined Manufacturing: Reference Architecture

Software-Defined Manufacturing: Reference Architecture

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International Symposium on Power Electronics, Electrical Drives, Automation and Motion, SPEEDAM

作者： Florian Frick Carsten Ellwein Armin Lechler Michael Neubauer Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798350387599

ISBN: (纸本)9798350387605

Solving current challenges in the manufacturing industry, for example, ever-increasing productivity, growing un-certainty and flexibility, as well as the digitalization, requires a shift in paradigm of how industrial production is thought, engineered and implemented. Software-defined Manufacturing (SDM) replaces the production-system-centric approach by a production-solution-focused approach. Solutions are engineered virtually using software tools and defined by standardized model. The physical implementation of a software-defined solution is performed using services, that deploy the models on resources, representing available assets. The consistency between models and implementations of solutions enables continuous processes. SDM is an open ecosystem-based approach, combining key technologies, models and services. In this paper, a reference architecture for the SDM ecosystem is presented. Based on the definition of resources and solutions, the SDM-core is introduced connecting both. The core consists of data models and essential services, including asset management, orchestration and access management. The holistic architecture also includes human roles and external entities. The reference architecture is validated using representative use cases that were identified based on a large-scale use case study. The architecture is considered as a foundation for SDM and will be followed by a series of detailed publications regarding resources, technologies, use cases and applications.

关键词： Manufacturing industries Productivity Ecosystems Computer architecture Turning Real-time systems Power electronics

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Concept of an Initial Requirements-Driven Factory Layout Planning and Synthetic Expert Verification for Industrial Simulation Based on LLM

Concept of an Initial Requirements-Driven Factory Layout Pla...

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IEEE International Conference on Industrial Informatics (INDIN)

作者： Erik-Felix Tinsel Armin Lechler Oliver Riedel Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331527471

ISBN: (纸本)9798331527488

The value added by virtual commissioning of in-dustrial production systems is evident through significant cost savings achieved via early error detection. Detecting errors early in the development process enhances project success. However, the development of simulation models is associated with manual effort, particularly during the early phases of the project when it comes to creating the first models. To reduce costs and increase automation in the redesign of simulation models, a novel concept is presented that automatically transforms unstructured customer requirements into initial model placeholders within a simulation environment. The approach employs a large language model to identify necessary processes and machines, estimating their dimensions and positioning them relative to each other. The output is then converted to a simulation model format and imported into a simulation environment for further refinement. To verify the solution, a synthetic expert, trained using a large language model, learns the probability correlations between plant types, machines, and processes, thereby enabling a more accurate assessment of the resulting simulation model.

关键词： Solid modeling Costs Correlation Automation Three-dimensional displays Computational modeling Large language models Layout Transforms Production facilities

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Endpoint Architecture for Distributed Real-Time Applications Based on TSN

Endpoint Architecture for Distributed Real-Time Applications...

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IEEE International Workshop on Factory Communication Systems (WFCS)

作者： Stefan Oechsle Florian Frick Moritz Walker Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798350319347

ISBN: (纸本)9798350319354

Distributed real-time applications perform deterministic tasks across multiple connected compute platforms, referred to as endpoints. Deterministic behavior of the communication and the compute are prerequisites, but coordinating and managing both in a holistic way is a significant challenge. Converged real-time networks based on Time-Sensitive Networking (TSN) are considered the key enabler across industries for the required connectivity. To date, the potential of TSN cannot be exploited due to many sub-standards still being under development, gaps in the management and configuration functions, lack of best practices and unresolved integration with higher application layers and domain specific engineering. Previous work, focusing on a modular open source framework for the engineering and management of distributed real-time applications, identified a unified approach for TSN-based endpoints as a key gap. This paper presents a novel endpoint architecture to operate, engineer and manage distributed real-time applications by seamlessly integrating real-time networking and compute. The architecture provides interfaces to a central engineering, allows to integrate centralized as well as distributed network management and offers a unified data management. An abstraction layer for applications allows the efficient use and complements existing open source solutions.

关键词： Industries Communication systems Focusing Distributed databases Computer architecture Real-time systems Production facilities

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Orchestration of Heterogeneous, Distributed, Real-Time control Containers

Orchestration of Heterogeneous, Distributed, Real-Time Contr...

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IEEE International Conference on Industrial Informatics (INDIN)

作者： Moritz Walker Leonard Rupietta Armin Lechler Michael Neubauer Alexander VerI Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331527471

ISBN: (纸本)9798331527488

In today's global market, manufacturers must be highly adaptable, producing profitably smaller batches. Disin-tegrating hardware and software and embracing modern IT concepts like containerization and Service-oriented Architecture enable this flexibility. While offering rapid reconfiguration, these approaches add complexity. Orchestration tools aid in analyzing response times, workload mapping, and parameter selection for containerized real-time applications. However, current tools struggle with managing distributed, heterogeneous, real-time apps. This paper proposes an orchestration solution based on Compositional Performance Analysis and Genetic Algorithm to optimize task allocation across diverse computing resources. The approach enables the orchestration of heterogeneously scheduled, container-based. distributed real-time systems.

关键词： Globalization Real-time systems Software Hardware Service-oriented architecture Performance analysis Time factors Resource management Informatics Genetic algorithms

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Analysis of the Applicability of Cloud Computing Scaling Techniques for Real-Time Workloads of Industrial control Systems

Analysis of the Applicability of Cloud Computing Scaling Tec...

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IEEE International Conference on Industrial Informatics (INDIN)

作者： Rebekka Neumann Florian Frick Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331527471

ISBN: (纸本)9798331527488

A key feature of cloud computing is elasticity, which enables resources to be allocated and de-allocated according to dynamic application demands. The evolution of Industrial control Systems (ICS) is moving towards a distributed converged infrastructure that incorporates computing and communication resources as well as software, replacing dedicated hardware running control applications. While modern ICS and cloud environments share similarities, the corresponding applications differ significantly in their execution models and timing requirements. To enhance the flexibility of ICS, control applications must adapt to changing requirements throughout operation, resulting in varying workloads. The potential for dynamic scaling in ICS is considerable, but is not yet being fully exploited. The objective of this paper is to examine the extent to which state-of-the-art cloud autoscaling concepts are applicable to the scaling of real-time workloads and to propose enhancements to these concepts in order to enable the implementation of dynamic auto scaling of real-time workloads. In conclusion, the fundamental concept of cloud autoscaling can be applied, but must be extended, in particular to ensure deterministic resource provisioning and to improve task isolation in order to guarantee predictable task timing behaviour.

关键词： Cloud computing Industrial control Elasticity Dynamic scheduling Real-time systems Software Hardware Timing Integrated circuit modeling Informatics

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