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NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
1
The University of Michigan, Ann Arbor
Engineering Research Center for
Reconfigurable Manufacturing Systems
Virtual Fusion: The Complete Integration of Simulated andActual
William Harrison, Graduate StudentJames Moyne, Associate Research Scientist
Dawn Tilbury, Professor
January 14, 2008
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Demonstration
• Run the Reconfigurable Factory Testbed with nosimulated parts
• Replace an entire cell
• Add a cell to the existing infrastructure
• Monitoring
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Inefficient Robot Throughput Low
Cell and Component Swapping in the RFT
Part
Motoman DA20
• 20kg payload/arm
• 13 dof
• “Jigless” operation
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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DEMO: Robot Swapping in the RFT
System Level Controller
CNC
CNC robot
Cell 2
Controller
Conveyor
Conveyor
Controller
CNC
CNCrobot
Cell 1
Controller
Supply Cellcontroller
Gantry
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Supply Cell : Adding a New Cell
• Replace existing manualpart loading station withnew automated system– Example: Overhead gantry
setup
– Simulating the hardwareand the PLC software
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Conveyor
CNC
CNC
CNC
CNC CNC
CNC
Hybrid Process Simulation: Normal Process
CNC
Conveyor
CNC
CNC
Hybrid Process Simulation: Hardwired SimulationHybrid Process Simulation: Hybrid ModeHybrid Process Simulation Extension: Monitoring
CNC
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Cyber-Physical System Integration
• Large amounts ofavailable datanecessitates state of theart interface– Desktop
– 3D Geowall
• Wide Scale Monitoring– In Plant (game engine)
– World Wide (2nd Life)
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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END
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Presentation Outline
• Problem
• Task and Purpose
• Virtual Fusion and Hybrid Process Simulation• Objectives, Deliverables, and Benefits• Application of Hybrid Process Simulation Methodology• Simulation and Modeling• Reality Science• Future Plans• Demo
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Problem: Cost (Ramp Up Time and Change OverTime can always be better)
• Simulation models are sometimes inaccurate
• Expensive to develop
• Centralized in one program and one simulationcompany
• Simulation models go unused after planning
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Task and Purpose
• Task: Reduce Cost by decreasing ramp up andchange over time
– Finding better ways to integrate simulation into thedevelopment process and throughout the product lifecycle
• Purpose of Presentation
– Show the technical developments on the ReconfigurableFactory Testbed
– Briefly introduce intellectual contributions thus far
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering # 12
Virtual Fusion: The Complete Integration of Simulated and Actual-Ongoing (Fall 06) ; Core Project; 1 Student; GM Partner
• Objectives
– Develop HILS methodology
for logic control verification
and validation
– Pre-launch validation,
online monitoring and
operator training
• Key Deliverables
– HILS tools and logic validation survey (CASE 2007)
– HILS implementation on ERC-RFT
– Methodology on use of HILS for logic validation
– Solution for HILS use in monitoring and operator training
• Benefits to Industry– Understand state-of-the-art of HILS in auto manufacturing
– Reduce launch time and downtime due to unanticipated behavior
– Provide platform for testing difficult-to-simulate components
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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Inefficient Robot Throughput Low
June 2008 Demo: Cell Swapping in the RFT
Part
Motoman DA20
• 20kg payload/arm
• 13 dof
• “Jigless” operation
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
# 14
Supply Cell : Adding a New Cell
• Replace existing manualpart loading station withnew automated system– Example: Overhead gantry
setup
– Simulating the hardwareand the PLC software
• Current status: VirtualCell is completed andintegration is beingtested
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
# 15
Fanuc Roboguide Integration
• Leverage Fanuc’s existing
simulation software for
system validation
• Roboguide: Fanuc’s robot
simulation software
– Same interface as real robot
– Execute actual program and
confirm motion path and logic
– Highly accurate simulation of
movement and application
commands
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
# 16
• Virtual world reflects
real time “ground truth”
of the plant floor
• Improved information
visualization leads to
better understanding of
system operation, rapid
fault diagnosis and
reduced downtime
Monitoring System Real Time Data
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
# 17
Milestones and Future Plans
June 2008
Nov 2009
Dec
2008
May 2009
• Motoman Cell Level Swap
• Robot Emulator Validation
• Supply Cell Addition
• Fanuc Low-Level Simulation Integration
• Methodology for Validation by Swapping
• Methodology for Evaluating System Fidelity
• Monitoring System Implementation on RFT
February 2007
Dec
2008
January 2009
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