Manufacturing facility simulation linked with physical system (A proposal for standardization of components to construct facility simulation)

Abstract

This paper discusses the effectiveness of manufacturing facility simulation linked with physical systems on value chain activities. The activities on manufacturing preparation and implementation processes of manufacturing systems have been improved by manufacturing facility simulation. This method originates from research on the concept of virtual manufacturing environment in the early 1990s. The equipment or facility simulation layer corresponding with the standard hierarchy model of enterprise and control integration is defined. Facility and control model utilized for whole facility lifecycle and its configuration are proposed as a standardization candidate of the reference model. The model consists of digital data of many components including mechanical and control properties like 3D data of mechanism, kinematics, axis, joint, sensor signal and actuator signal. The model should be the standard because the property information of components is only provided by parts suppliers. The facility simulation is linked with both physical controllers and their simulators by standard communication middleware connecting various communication protocols of Real-time Ethernet and fieldbus. After the detail system configuration is described, the applied case studies of improving engineering chain activities in automobile manufacturing are explained. The case studies indicate these systems are efficient to shorten the development period of flexible manufacturing facilities including robots and fixture jigs and to reduce the development cost.

Keywords

• virtual manufacturing
• reference model
• communication middleware
• cyber-physical system
• plc
• virtual commissioning