Tecnomatix Plant Simulation Worldwide User Conference 2016

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1 KarisPro Autonomous Intralogistics Robots for Industry 4.0 The Internet of Things proclaims independent acting individual objects. Can they be modeled in a discrete event simulation tool? Hao Jiang + Stefan Pfaff PPI-Informatik Sindelfingen Germany Agenda What is KarisPro? The ject See a Karis AGV live Simulation in Karis Development Simulation done by Univ. Freiburg for Control System Development Simulation done by PPI for Logistics Planning Karis Plant Simulation Library Map, navigation, path planning Karis Vehicle and Battery management Karis Order management - Auction Multi robot Swarm behavior and Intelligence Periphery the Process 2

2 - What is it? Kleinskaliges Autonomes Redundantes IntralogistikSystem in der Produktion Smallscale Autonomous Redundant Intralogistic System in Production (Saris Pro) 3 What is so special about? Quick and easy commissioning by customer without changing the infrastructure and environment. Flexible load adapter by modular system design Scale ability and robustness through decentral controls Location independent, mobile Human -Machine-Interface Safe Collaboration by highly integrated Safety Features Extended functionality through innerchangeable load modules 4

3 Who is behind the ject? is a multi company research project funded by the BMBF started in 2014 until Karis - form the outside Change module index Change module connector Load plate LEDs Hood Wifi Antena 2 Wifi Antena 1 6

4 Karis under the hood Lift screw Laserscanner Mirror for blindman s stick Pot-Drive Accu Energytransmitter 7 Karis under the hood Motor change module index Lift scre 3 Lift screw 2 Navigation control Saftey controller Liftscre w1 Drive control Lift belt drive Change module index 8

5 See the AGV live 9 Simulation by Uni Freiburg Uni Freiburg is using ROS (Robot Operating System) and Stage for development and simulation of the KARIS navigation controls. This includes solving the complex task of multi robot motion planning. To avoid collisions between the robots a decoupled approach by combining decentralized path planning methods and swarm technologies was implemented. 10

6 Simulation by PPI The role of PPI in the KARIS project was to develop a logistic simulation (library) to support the logistics planning for the two Pilot Sites BOSCH and AUDI. Tasks for Simulation are: Number of KARIS vehicles necessary for desired system output? Number and location of battery charging stations? Best parameters settings for energy management? Optimize parameters settings used in Order Management strategies, like priorities, weights for auction bids etc. Support the planning of KARIS periphery, the Production Process. 11 Plant Simulation Karis Library Plant Simulation KARIS Library Map, navigation, path planning KARIS Process Interface (Station) Karis Vehicle and Battery management Multi robot Swarm behavior and Intelligence Karis Order management - Auction Results and Reports Periphery the Process 12

7 MAP ( Layout ) The map used in real KARIS is grid based and recorded by one KARIS during an initial drive through the environment using the laser scanner data. Planning Phase of KARIS Projects: Map data is not available. Library contains an editor to manually generate maps or used CAD / XML Data to generate maps and stations for simulation. Analyze and Optimize existing KARIS Systems: Interface to read in original KARIS map data. Stations can be located manually in these maps. KARIS scan data map. Generated maps. Map Editor 13 Structure of the Grid Map The simulation grid map consists out of multiple Plant Simulation Track Objects. Each Track is representing one cell of the grid map. Standard Track length is equal to grid spacing. KARIS is a Plant Simulation Transporter Object. Moving forward in 4 directions: NorthEast, East, SouthEast, South. Moving backwards in 4 directions: SouthWest, West, NorthWest, North. If KARIS is moving in diagonal directions Track length is dynamically adjusted to length = grid spacing * 1,141 using the entrance/exit control of the Track triggered by Transporter front / rear depending on direction. 14

8 Karis Path Planning using A* Real world KARIS is using the A* Algorithm for path planning. From Wikipedia, the free encyclopedia: In computer science, A* (pronounced as "A star" ( listen)) is a computer algorithm that is widely used in pathfinding and graph traversal, the process of plotting an efficiently traversable path between multiple points, called nodes. Noted for its performance and accuracy, it enjoys widespread use. However, in practical travel-routing systems, it is generally outperformed by algorithms which can pre-process the graph to attain better performance, [1] although other work has found A* to be superior to other approaches. [2] Peter Hart, Nils Nilsson and Bertram Raphael of Stanford Research Institute (now SRI International) first described the algorithm in [3] It is an extension of Edsger Dijkstra's1959 algorithm. A* achieves better performance by using heuristicsto guide itssearch. We implemented the same Algorithm in Plant Simulation to ensure the same behavior and performance in virtual world. 15 Battery control and Energy Management For modeling the Energy Consumption of a KARIS during movement the standard Plant Simulation functionality and parameters are used. For docking and load change a specific control deducts the battery loading according to parameter settings. The KARIS specific energy Management functions: When to stop taking orders and drive to charge mat? Which charge mat to choose? When to leave the charge mat? How much juice the charge mat delivers? are implemented in special controls. 16

9 Decentral Order Management - Auction Real World Karis is using a decentral (no central control instance existing) agent based approach for Order Management. Each incoming Order is distributed to each Karis in the System Each Karis is evaluation the Order requirements and participates in an auction sending in an individual bid. The KARIS with wins the auction takes the order and executes it. The are certain criteria's applied to calculate the bid: Time to reach the start point of the new order Estimated remaining time to fulfill current order Estimated time to drive to start point of new order. Battery capacity Energy consumption to fulfill the current order Energy consumption to fulfil the new order 17 Decoupled Path Planning and Swarm Behavior Real World KARIS uses Swarm Behavior: Instead of a central coordination, a proper behavior which is directly selected according to the context is used by the robot to keep cooperating with others and to resolve path collisions. The same algorithms to detect the situation and select the proper behaviors are implemented in the KARIS library. Symbol Behavior 18

10 Modeling the process KARIS Periphery Modelling the production environment and processes where KARIS is used is an easy standard task for Plant Simulation. There are 2 Interfaces between Process and KARIS: Material Flow Interface the KARIS Station. The HMI for entering Orders, Confirmation and other Data interaction between Process and KARIS. BOSCH Pilot Scenario: 3 Assembly Lines Material transport to / from central storage 5 different transport processes supported by KARIS 19 The Station Object Interface between KARIS and WORLD The abstract KARIS Station Object serves as Universal Interface between KARIS and the World. Stations are the Starting-Point and End-Point of each KARIS Transport and can also serve as Battery Charging Mats and Home A Station can be configured to provide different functionalities: Loading Unlaoding Battery charging Homepos Load and Unload Load and Charge Unload and Charge Load + Unload and Charge Charge and Homepos 20

11 Your competent partner for simulation und optimization PPI - Informatik Dr. Prautsch & Partner Contact: Stefan Pfaff Managing Partner phone: mobile: stefan.pfaff@ppi-informatik.de Posenerstr. 1 D Sindelfingen Germany Tel: / Fax: / info@ppi-informatik.de 21