An Experimental Platform for e-manufacturing

Transcription

1 An Experimental Platform for e-manufacturing and Advanced Control IFAC World Congress, July 6-11, 2008, Seoul, Korea Franck Fontanili, associate professor Ecole des Mines d Albi-Carmaux (France) Departement of Industrial Engineering

2 Outline Introduction Problem and proposed solution Physical system Information system Educational applications Research applications Conclusions and perspectives Keywords Control education; Command & control systems; Remote and distributed control 2

3 Introduction Globalisation of production Today and in a near future y Customer y Customer Production Manager in Toulouse (FRANCE) Plant 2 ASIA Plant 3 ASIA Plant 1 AMERICA remote control of several plants all around the world in real time. 3

4 Problem and proposed solution How to train students to e-manufacturing and advanced control? By using an experimental platform intended to put them in a «real world» situation as a production Site #1 Site #2 manager. Real Production System Real Production System Real Production System internet Information System Site #3 Experimental Platform Group of students 4

5 Physical system - Functions Assembly line with 3 main functions: Empty pallet Pallet loaded with finished product Master component Load/Unload Serial workstation A1 Pallet with master component Finished product Pallet with assembly in progress Forward to workstations A2 Pallet entering Loop conveyor workstation Components Assemble components A3 Bypass workstation 5

6 Physical system - Product Product easy to assemble/disassemble Different combinations of components Example of assembled product Lid (Co) Box (B7) H7-2 Cylinder (Gl1) Sub-assembly (Tu+Bo+Jo+Gs3) Cylinder (Gl3) 6

7 Physical system - Process 6 workstations located around free automated conveyors Products are transfered on pallets with RFID tag W orkstation #6 U nload product W orkstation #5 Insert sub-assem blies (m anual) W orkstation #4 Close box W orkstation #1 Load box W orkstation #2 Insert com ponents W orkstation #3 Insert com ponents (m anual) 7

8 Information system - Functions 3 main functions/applications for make-to-order manufacturing Products catalog Order status Product needs Order products A1 customer e-commerce Waiting orders Orders and campaign status Orders planning A2 Waiting campaigns Production manager e-plan OPC informations from physical system Availability of manufacturing system Orders performance A3 Job orders e-mes e-mes users 8

9 Information system Layout A network of PLC and an OPC server on the site of the assembly line A host computer for software applications on another site linked to the first site with internet Server 1 OPC host PLC for Workstation 5 PLC for Load/Unload stations 1 & 6 Industrial Ethernet PLC for Workstation 4 Internet RASCOL site (production line area) PLC for Workstation 2 PLC for Workstation 3 Local network Server 2 Web applications host EMAC site (Information system area) 9

10 Applications for education The student must be in a situation close to the reality as a production manager His works consists in the remote control of a plant to satisfy customers in a make-to-order context Ability to mobilize: theoretical knowledge in operations management, process analysis and improvment, planning and scheduling, etc. practical knowledge in programming PLC, robots, failure diagnostic and maintenance, etc. 10

11 Example of educational appli. Data: orders coming from customers with different references, quantities, due dates Objective: delivery of the products as fast as possible and in the right quality Work to be done in 2 main steps: Preparation and optimisation of campaigns thanks to simulation software tool and MES database Execution on the real system with remote release and control 11

12 Research applications Possibility to validate research works on structure, organization and control of remote production sites. Take into account recent technologies: automated machines, robots, transferts, RFID, MES, etc. More realistic research and quicker to transfer to industrial sites. 12

13 Example of research appli. Problem: how to know if critical events (breakdown, urgent orders, stockouts, etc.) have a consequence on the objective (delivery date)? Research work: use discrete-event simulation in real-time and on-line to control a real process. 13

14 Conclusions and perspectives The platform will allow the students to play the role of production manager. Education applications are almost designed to train students with real-world situations. Other applications are in progress for education and research purposes. 14

15 Any questions? 15