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A Multicore control System Architecture as an Operating Platform for Industrial Digital Twins

Procedia CIRP 2023年 118卷 294-299页

作者： Lars Klingel Karl Kübler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Seidenstr. 36 70174 Stuttgart Germany

Digital Twins are seen as one of the core technologies and enablers of Industrie 4.0. There are various definitions of the term Digital Twin, but most agree that they are digital representations supporting the real production system throughout its lifecycle by providing models, data-integration and online-optimization. Currently, there are no implementations of Digital Twins to be used productively, which fulfill all parts of this definition. This work focuses on the simulation part of Digital Twins and the real-time requirements which arises from an online calculation. An approach that uses models of virtual commissioning, which are integrated in an industrial controller to tackle the problem of real-time calculation is presented. To enable the online simulation of complex and multi-physical models the simulation is parallelized and calculated on a multicore processor.

关键词： Industrial Digital Twin Co-simulation Partitioning Virtual Commissioning

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Deep Learning-Based Instance Segmentation for Feature Extraction of Branched Deformable Linear Objects for Robotic Manipulation 19

Deep Learning-Based Instance Segmentation for Feature Extrac...

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

作者： Zürn, Manuel Kienzlen, Annika Klingel, Lars Lechler, Armin Verl, Alexander Ren, Shiyi Xu, Weiliang Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstr. 36 Stuttgart70174 Germany The University of Auckland Department of Mechanical and Mechatronics Engineering 20 Symonds St. Auckland1001 New Zealand

ISBN: (纸本)9798350320695

Branched deformable linear objects, like wire harnesses, are vastly used in the electrical industry to interconnect multiple electronic components while allowing small relative motions. Their deformable nature gives them an infinite-dimensional configuration space, which is challenging for robotic manipulation and requires sensor feedback about the actual configuration. Cameras have been used before in automation attempts as sensor feedback of branched deformable linear objects. However, image processing is sensible to occlusions and unstructured environments. This paper presents a method of using deep learning-based instance segmentation networks to extract topological features like connectors, clips, branch points and overlapping points on the branched deformable linear object. The topological features originate from features that can be used for matching a stretched representation of the branched deformable linear object to its sensor representation. Our results show that the network is capable of extracting the features for different datasets with high accuracy. Furthermore, this paper evaluates the use of preliminary results in the training process to facilitate annotation by predicting the labels. For now, this paper only uses 2D images of the branched deformable linear objects. Future work will also use depth images, such that individual deformable linear object features, such as length or radius, can be extracted from the images. We anticipate the usage of wire harness automation with robotic manipulation, augmented reality support of the worker or quality control of wire harnesses. © 2023 IEEE.

关键词： Feature extraction

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Self-adaptive digital twin reference architecture to improve process quality

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Procedia CIRP 2023年 119卷 867-872页

作者： Ann-Kathrin Splettstößer Carsten Ellwein Andreas Wortmann Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstr. 36 D-70174 Stuttgart Germany

The aim of software-defined manufacturing is a more adaptable production through software. This requires highly adaptive, versatile cyber-physical production systems (CPPSs), which react flexibly to changes and perform crucial adjustments. Self-adaptive digital twins (DTs) enable adaptability through monitoring the behavior of a CPPS, identifying problems, and determining adjustments for the optimization of processes. DTs work with an idealized representation of the CPPS. Changes in system behavior that negatively impact the process execution, e.g., caused by tool wear or variations of environmental influences, and, thus, the quality of the resulting product, are ignored. This ignorance leads to defective products, sub-optimal product quality, and hazardous CPPS states. To mitigate this, we present an approach to incorporate quality awareness into a model-driven reference architecture of a self-adaptive DT. The devised concept automatically analyzes and optimizes system behavior. To this end, a component for quality evaluation extends the reference architecture. The DT and CPPS are connected via OPC UA. To validate the approach, a fiber laser machine is utilized. The DT can operate both on a physical and a virtual laser machine.

关键词： Digital Twin Model-Driven Development Software-Defined manufacturing Quality Awareness

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A modular configuration and management framework for distributed real-time applications based on converged networks using TSN

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Procedia CIRP 2023年 118卷 38-43页

作者： Stefan Oechsle Florian Frick Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Seidenstr. 36 70174 Stuttgart Germany

Industrial control systems are distributed real-time applications deployed on field and controller devices, connected by fieldbuses. Their lack of interoperability, mutually and towards IT-systems, is a major obstacle for the digitalization. Converged networks are considered as the solution across industries with Time-Sensitive Networking (TSN) as the enabling technology. To ease the adoption of TSN for industrial automation, a modular framework was developed for future engineering tools. The core of the framework consists of a module management including interfaces and a YANG-based datastore, maintaining a system-wide data model. Modules are provided for network configuration implementing CUC-functions, monitoring and container-based application and deployment.

关键词： Time-Sensitive Networking distributed real-time applications engineering framework

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Online Parameterization of a Milling Force Model using an Intelligent System Architecture and Bayesian Optimization 55

Online Parameterization of a Milling Force Model using an In...

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55th CIRP Conference on manufacturing systems, CIRP CMS 2022

作者： Schmucker, B. Trautwein, F. Hartl, R. Lechler, A. Zaeh, M.F. Verl, A. Institute for Machine Tools and Industrial Management Iwb Technical University of Munich Boltzmannstr. 15 Garching85748 Germany Institute for Control Engineering of Machine Tools and Manufacturing Units ISW University of Stuttgart Seidenstr. 36 Stuttgart70174 Germany

This paper presents an efficient and industry-ready system architecture that enables both the control of machining operations and the high-frequency acquisition of controller data and external sensor signals. Using the recorded data, a dexel-based mechanistic cutting force model, which enables the estimation of cutting forces for complex tool geometries in arbitrary machining operations, is parameterized via an instantaneous cutting force identification method. In the introduced identification method, Bayesian Optimization and Dynamic Time Warping are combined to avoid time-consuming and error-prone synchronization of measurement and simulation. The suitability of this approach was demonstrated by performing cutting experiments at various radial depths of cut and feed rates per tooth. Thereby, a good agreement between simulation and measurement could be observed. © 2022 The Authors. Published by Elsevier B.V.

关键词： Data Analytics Industry 4.0 machine tools Process Simulation

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Requirements and Challenges in the Configuration of a Real-Time Node for OPC UA Publish-Subscribe Communication

Requirements and Challenges in the Configuration of a Real-T...

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International Conference on Mechatronics and machine Vision in Practice (M2VIP)

作者： Rebekka Neumann Christian von Arnim Michael Neubauer Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

Factory automation is evolving from a hierarchical structure towards an interconnected architecture in which systems at different levels can communicate seamlessly with each other. This requires an appropriate replacement of proprietary fieldbus systems in the automation sector. A promising solution to implement cross-plane end-to-end real-time capable communication between computing nodes is proposed in literature. The usage of Open Platform Communication Unified Architecture (OPC UA) as the information model with the Publish-Subscribe (PubSub) communication mechanism in combination with Time Sensitive Networking (TSN) is presented to fulfill the requirements for message transmission. In contrast to the state of the art of configuring fieldbus systems, the configuration of such a real-time communication node has to be done manually. This process is complex, as deep knowledge in different domains is required. In this work we elaborate the requirements for such a communication node and present the resulting implementation challenges, which can be used as the basis for a configuration tool.

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Additive manufacturing of Ceramics opens the door to Components for Biomanufacturing Applications with high Functionality 6

Additive Manufacturing of Ceramics opens the door to Compone...

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6th CIRP Conference on Biomanufacturing, BioM 2024

作者： Scheithauer, Uwe Holtzhausen, Stefan Wiemer, Hajo Fraunhofer Institute for Ceramic Technologies and Systems Group Additive and Hybrid Manufacturing Winterbergstr. 28 Dresden01277 Germany TUD Dresden University of Technology Institute of Machine Elements and Machine Design Virtual Product Development Group Advanced Geometric Modeling And Analysis Dresden01062 Germany TUD Dresden University of Technology Institute of Mechatronic Engineering Machine Tools Development and Adaptive Controls Department of Machine Data Processing Dresden01062 Germany

Significant advancements in production technology, materials, component design, and data science foster innovation across industries, including biomanufacturing. Ceramic materials, adapted additive manufacturing processes, and novel construction methods hold immense innovation potential due to ceramics' exceptional thermal, chemical, and mechanical properties. Additive manufacturing enables the creation of intricate ceramic components with unprecedented functionality. Hybridizing manufacturing technologies and materials facilitates direct integration of additional features like sensors and actuators. Despite their potential, ceramic materials remain underutilized. This article aims to spark a discourse on leveraging high-performance ceramic components in biomanufacturing, leveraging superior material properties, innovative design methods, additive manufacturing, process data analysis, and AI. © 2024 The Authors.

关键词： Ceramic materials

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Safeguarded Continuous Deployment of control Containers through Real-Time Simulation

Safeguarded Continuous Deployment of Control Containers thro...

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International Conference on Emerging Technologies and Factory Automation (ETFA)

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

Static configurations and slow adaption to changing requirements characterize today’s production systems. In order to cope with variable external influences, these systems need to become more flexible. One building block towards meeting this requirement from the software perspective is employing quality-preserving processes to develop and update automation applications. While this condition applies to classical automation applications, it is increased if Software-defined manufacturing (SDM) is applied. Containers can be used to deploy software through orchestration. Orchestration covers initial deployment and the roll-out of new software versions. This makes it in theory possible to deploy automation applications, such as computerized numerical control (CNC) software. However, available tools from information technology cannot be used to orchestrate and update automation applications, as real-time requirements must be considered. This work presents an approach that supports orchestration, specifically the deployment and update process, of real-time containers safeguarded by real-time capable simulation coupled with the control system during the operation phase. It shows how to achieve the right timing for real-time software updates and how to prevent causing damage by observation and safeguarding through information obtained from the real-time simulation. Using real-time simulation in the operating phase, container-based control and real-time orchestration become safer and more applicable in industrial manufacturing systems.

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Reflection-based Prototyping Framework for OPC UA Servers for Companion Specifications

Reflection-based Prototyping Framework for OPC UA Servers fo...

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IEEE International Conference on Industrial Technology (ICIT)

作者： Moritz Walker Christian von Arnim Michael Neubauer Armin Lechler Oliver Riedel Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

Domain-specific Companion Specifications (CS) define OPC UA information models for specific use cases, devices, or industries and define how to use OPC UA in specific environments. A sample OPC UA server is required to evaluate an OPC UA CS and develop clients. Such a server needs to be easily changed on updates of the CS and must ensure that all instances comply with the specified OPC UA types. This paper introduces an OPC UA server prototyping framework that maps OPC UA instances to $\mathbf{C++}$ data types using reflection. Using OPC UA types for instantiation, all created instances comply with the CS. The mapping to $\mathbf{C++}$ data structures provides a simplified API for handling sample instances by enabling users with limited knowledge about OPC UA to build CS-conformant servers. Four use cases show the usefulness of the approach: OPC UA Events, OPC UA PubSub and creating CS compliant servers.

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Simulation-Based Predictive Real-Time Collision Avoidance for Automated Production systems

Simulation-Based Predictive Real-Time Collision Avoidance fo...

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IEEE International Conference on Automation Science and engineering (CASE)

作者： Lars Klingel Alexander Heine Steven Acher Niklas Dausend Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

The usage of simulation technology is deeply established in the development and commissioning of automated production systems. Impending collisions of moving kinematics, such as robots, can therefore already be detected with the help of simulations before the production system goes into operation. However, changes in the control software of production systems that occur in the operating phase are often not secured, which entails risk, especially in the age of cyber-physical and adaptive production systems. This work presents a predictive simulation-based approach for the online collision avoidance of automated production systems by enabling virtual commissioning simulations for the application in the operating phase. This allows a cost-efficient way to achieve the safe operation of production systems without the need of additional configurations and sensors.

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