Lecture Notes in Computer Science Edited by G. Goos and J. Hartmanis

168

Methods and Tools for Computer Integrated Manufacturing Advanced CREST Course on Computer Integrated Manufacturing (CIM 83) Karlsruhe, Germany, September 5 to 16, 1983

Edited by U. Rembold and R. Dillmann

Springer-Verlag Berlin Heidelberg New York Tokyo 1984

Editorial Board D. Barstow W. Brauer P. Brinch Hansen D. Gries D. Luckham C. Moler A. Pnueli G. Seegmeller J. Stoer N. Wirth

Editors

U. Rembold R. Dillmann Institut for Informatik III, Universit~it Karlsruhe Zirkef 2, 7500 Karlsruhe 1, West Germany

CR Subject Classifications (1982): 1.2.9, 1.2, J.2, J.6

ISBN 3-54042926-X Springer-Verlag Berlin Heidelberg New York Tokyo ISBN 0-38742926-X Springer-Verlag New York Heidelberg Berlin Tokyo

Library of Congress Cataloging in Publication Data. Advanced CREST Course on Computer Integrated Manufacturing (1983: Kadsruhe, Germany) Methods and tools for computer integrated manufacturing. (Lecture notes in computer science; 168) Includes bibliographical references. 1, CAD/CAM systems-Congresses. I. Dillmann, R., 1949-. II. Rembold, Ulrich. III. Title. IV. Series. TS155.6.A37 1983 670.42'? 84-5529 ISBN 0-387-12926-X (U.S.) This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically those of translation, reprinting, re-use of illustrations, broadcasting, reproduction by photocopying machine or similar means, and storage in data banks. Under § 54 of the German Copyright Law where copies are made for other than private use, a fee is payable to "Verwertungsgesellschaft Wort", Munich.

© by Spnnger-Verlag Berlin Heidelberg 1984 Printed in Germany Printing and binding: Beltz Offsetdruck, Hemsbach/Bergstr. 2145/3140-54321

INTRODUCTION

BY

ULRICH REMBOLD

Fakuit~t fur Informatik

Universit~t Karlsruhe

7500 Karlsruhe

Federal Republic of Germany

This book contains the lecture notes of the Advanced Course on Com-

puter Integrated Manufacturing (CIM '83), held at the University of

Karlsruhe from the 5th to 16th of September 1983, Karlsruhe, Feder-

al Republic of Germany. The course was financed by the Ministry of

Research and Technology (BMFT) of the Federal Republic of Germany

and by the Commission of the European Communities.

~V

Manufacturing contributes to over 60% of the gross national product of the highly industrialized nations of Europe. The advances in mechananization and automation in manufacturing of international competitors are seriously challenging the market position of the European countries in different areas. Thus it becomes necessary to increase significantly the p~oductivity of the European industries. This has prompted many governments to support the development of new automation resources. There are also good engineers needed to develop the required automation tools and who apply these to manu- facturing. It is the purpose of this course to teach and discuss new research results in manufacturing with engineers who face the chal- lenge to building the future factories.

Early automation efforts were centered around mechanical gear and cam-technology and hardwired electrical control circuits. Because of the decreasing life cycle of most new products and the enormous model diversification, factories cannot be automated efficiently any more by these conventional technologies. With the digital com- puter, its fast calculation speed and large memory capacity, a new tool was created which can substantially improve the productivity of manufacturing processes. The computer can directly control pro- duction and quality assurance functions and adapt itself quickly to changing customer orders and new products. It allows the automation of long and short range forecasting, product design, process plan- ning, production scheduling and manufacturing control. The flow of information through a plant can be monitored and corrective action can easily be initiated if necessary. Probably the most important asset of the computer is its capability to integrate the entire man- ufacturing system from product design to fabrication. Its ability to make decisions will contribute to the conception and design of flexible manufacturing systems. With the progress of the artificial intelligence activities and with powerful low cost computing equip- ment, it will be possible to conceive expert systems for manufactur- ing. Upon entry of a product order they will be capable to plan and supervise automatically the production process. This will be real- ized with the help of decision rules and a knowledge data base about the production process and the available manufacturing resources.

The object of this course is to discuss advanced and future CAD/CAM technologies. Of course, the vast scope of manufacturing cannot be satisfactorily presented in a two weeks' series of lectures. Thus only those topics which are of common interest to many manufacturing organisations and which appear to be very important in the future are selected. In addition, an attempt is made to present to the au- dience the computer activities in manufacturing as an entity. For this reason the lecture notes can be used for courses covering this subject.

The contents of the course include the following topics:

- Modular Computer Controls for Manufacturing Equipment - Design of Production Control and Flexible Manufacturing

Systems - CAD Systems and their Interface With CAM - Technological Planning for Manufacture - Economic Analysis of Manufacturing Systems - Quality Assurance and Robot Vision - The Interface of Process Planning with Production and

Facility Planning - Productl Design for Assembly - Productlion Control and Information Systems - Programming of Industrial Robots - Methods of Artificial Intelligence in Robotics - Programming of Vision Systems - Social Aspects

This course is a continuation of the course "Computer Aided Design, Modelling, Systems Engineering, CAD-Systems" held at the Technical University of Darmstadt, September 8-19, 1980. The lecture notes were published in 1980 by the Springer Verlag under the same title, and edited by J. EnCarnacao. Because of this preceeding course it was decided not to repeat fundamental aspects of CAD. However, an attempt is made during the first lectures to show how with the aid of the computer design can be interfaced with manufacturing and how information for'production is automatically generated by the design- er.

The lectures of the course were prepared and presented by interna- tionally known outstanding technical experts from several countries. They are:

- R. Dillmann, University of Karlsruhe, Karlsruhe, Germany - G. Doumeingts, University of Bordeaux, Bordeaux, France - M. Gini, Politecnico of Milan, Italy - ~ Grabowski, University of Karlsruhe, Karlsruhe, Germany - F.- L. Krause, IPK-Berlin, Berlin, Germany

F. Leimkuhler, Purdue University, West-Lafayette, Indiana, " USA - P. Levi, University of Karlsruhe, Karlsruhe, Germany

C. ~ Liu, Purdue University, West-Lafayette, Indiana, USA - A. Redford, University of Salford, Salford, Great Britain - ~ - W. Scheer, University of Saarland, Saarbr~cken, Germany - G. Spur, IPK and Technical University of Berlin, Berlin,

Germany

All these contributors deserve words of sincere thanks for their ex- cellent lecture notes and presentations.

In order to organize this course and to discuss its contents, a se- minar was held with the lecturers in April 1983 at Karlsruhe. At that time the final topics were agreed upon and an attempt was made to derive at a common terminology.

All lecturers should be congratulated for the prompt delivery of their course notes. Thus it was possible to issue copies of the notes to all participants at the beginning of the course.

VI

There were many people who helped to prepare the course:

Dr. R. Dillmann did the principal work to get the course organized. Secretarial help was given by Mrs. ~ Jahn-Held and Mrs. B. Seufert. Mr. B. Rembold and Mr. W. Wirth were responsible for the tedious job of handling the mailing and other supporting activities.

The editor would like to express his gratitude to all the people who contributed to the success of this course.

Karlsruhe, August 1983 Ulrich Rembold

TABLE OF ~ S

PART I: BCONOMIC ASPECT OF CIM SYSTEMS AND FMS, CAD/CAM DESIGN OF FMS

CAD-Systems and their Interface with CAM

H. Grabowski and R. Anderl

I. Introduction

2. Philosophy of the Application of CAD-Systems

3. Software Structure of CAD-Systems

4. Computer Internal Model

4.1 Different Geometric Models for CAD

4.2 Importance of Technology oriented M~del for CAD/CAM

5. Interfaces of CAD-Systems

5. I Data Manipulation Language (DML)

5.2 Initial Graphics Exchange Specification (IGES)

5.3 Graphical and Kernel System (GKS)

6. Integration of the Manufacture Planning Process

6. I Planning Process based on CAD-Models

6.2 NC-Machine Tool Progr~g based on CAD-Models

7. Economic Aspects

8. Conclusion

TECHNOI/]GICAL PLANNING FOR MANUFACTURE

Methodology of Process Planning

G. Spur, F.-L° Krause and W. Turn, ski

I. Introduction

2. Tasks of Process Planning

3. Generation of the Process Plan

4. Principles of Process Planning

Development of APT and EXAPT

G. Spur, F.-L. Krause and L. Sidarous

I. APT-System

2. EXAPT-System

2. I Progr~g of N/C-Turning Operations

2.2 Progr~g of Drilling and Milling Operations

2.3 Prograrsui/ug of Punching, Nibbling, and Flame-Cutting Operations

2.4 Progranming of Wire-Eroding Operations

2.5 Files for the Registration Working Stock Data

3

4

9

13

14

18

20

22

24

28

31

33

35

41

44

53

53

53

54

57

57

60

60

62

63

64

65

66

66

VIII

Working Techriques of Computer-Aided Process Planning

G. Spur, F.-L. Krause and H.-M. Anger

I. Dialog Processing

2. Algorithms

3. Decision Tables

4. Data Files

Graphical Simulation of Manufacturing Processes in Process Planning

G. Spur, F.-L. Krause and W. Grottke

Systems for Cc~puter Aided Process Planning Including Quality Control

G. Spur, F.-L. Krause and H.-M. Anger

I. AUTAP-System

2. ARPL-System

3. CAPEX-System

4. CAPP-System

5. DISAP-System

6. DREKA~-System

7. PREPLA-Syste~

8. CAPSY-System (Inspection Planning)

The CAPSY Process Planning System

G. Spur, F.-L. Krause and W. Turowski

Planning of Assembly Sequences

G. Spur, F.-L. Krause and W. Grottke

N/C-Technology

G. Spur, F.-L. Krause and W. Turowski

N/C-Prograrmling on the Shop Floor Using Graphical Simulation Techniques

G. Spur, F.-L. Krause and W. Turowski

Progr~g of Robots Using Graphical Techniques

G. Spur, F.-L. Krause and L. Sidarous

Integrated Aspects of Technological Planning

G. Spur, F.-L. Krause and W. Grottke

68

68

71

72

74

79

85

85

87

88

90

91

93

94

96

100

106

113

119

124

133

IX

Production Control and Information Systems

A.-W. Scheer

138

I. Strategies for the Selection of Software Packages in Production 138

2. Data Management Requirements for Production Control 145

2. I Development of a Data Base Schema for Primary Data 145

2.1 .I Bill of Materials 145

2.1.2 Work Descriptions 148

2. I .3 Manufacturing Equii1aent 150

2.2 Special Cases of Variant Production 150

2.3 Data Manage/ne~t in Software Packages 153

2.3. I Conventional File Management 153

2.3.2 Specialized Data Base Systems 153

2.3.3 General Data Base Systems 153

2.3.4 System-Independent Data Bases 154

2.4 Future Developments in Data Management 154

3. Planning Strategies for the Implementation of Production Control Systems 160

3.1 Planning Stages 160

3.1. I Master Production Scheduling 160

3. I. 2 Material Requirement Planning 161

3.1.3 Capacity Scheduling 162

3. I .4 Job Shop Control 166

3. I. 5 Data Collection 166

3.2 Implementation Strategies 167

4. The Interface between CAD and Production Control 171

5. The Interface between Production Control and Marketing 172

5. I Master Production Scheduling 172

5.2 Order Handling 176

6. Factors Influencing the Acceptance of Production Control Software 177

Evolutionary Trends in Generative Process Planning

C.R. Liu

Abstract

Introduction

The Principal CAPP Methodologies

Generative Process Planning

4. I Extended Part Programming Systems

4.2 GPP Using Decision Tables and Tree Structures

4.3 Iterative Algorithm~

4.3. I Recursive Process Plar~ing

4.4 The Concept of Unit-Machined Surfaces

I.

2.

3.

4.

179

179

179

179

180

181

181

183

183

183

4.4.1 COFORM

4.4.2 APPAS

4.4.3 AUTAP and AUTAP-NC

4.4.4 M~re Sophisticated GPP Systems

4.4.4.1 STOPP

4.4.4. I. I Preprocessing

4.4.4.1.2 Construction of SPC Records

4.4.4. I. 3 Postprocessing

4.4.4.2 CIMS/DEC, CIMS/PRO

5. Adequacy of the Existing GPP's in the Wake of New Develol~nents

5. I Recent Trends in the Design of CMS Control Systems

6. Dynantic GPP Using Pattern Recognition Techniques: A New Concept

6. I Proposed Representation Schemes

6. I. I Object Representation

6. 1.2 Machine Tool Representation

6.2 Process Planning Steps (briefly)

6.2. I Flexible Planning Logic

6.2.2 Identification of Surface Precedences

6.2.3 Selection of Machines, Tool Bits and Clamping Positions

6.2.3.1 Theorem I

7. Concluding Remarks

183

184

185

186

186

186

187

187

187

187

187

191

191

191

191

192

192

192

192

192

192

Methodology to l~sign Computer Integrated Manufacturing and Control of

Manufacturing Units 194

G. Doumeingts

I. The Need for Methodology and Conceptual Model in C.I.M. 195

I. I The Use of Design Methodology 195

I. 2 Complexity of Computer Integrated Manufacturing 196

1.3 Conceptual Model in CIM Syste/n 198

I. 3. I The Notion of System 198

I. 3.2 Conceptual Models 198

1.3.2. I CAM-I Conceptual Model 198

I .3.2.2 ICAM Architecture 199

1.3.3.GRAI Conceptual Model 200

I. 3.3. I Physical System 200

1.3.3.2 Control System 200

1.3.3.3 GRAI Conceptual Model: The Hierarchical Structure

of Decision Centers 201

1.3.3.4 GRAI Conceptual Model: Structure of a Decision Center 201

2. Method for Designing Production Control System 210

2.1 SSAD Method: Structured System Analysis and Design 210

2.2 IDI~, Modules, O, I and 2: ICAM Definition 211

Xl

2.3 GRAI Method

2.3. I Analysing Process

2.3. I. I Top Down ~lysis

2.3. 1.2 Bottom up _Analysis

2.3. I. 3 Analysing Results

2.3.2 Designing Process

2.3.3 Conclusion

3. Design of Flexible Manufacturing System Using Modelling Tec.hniques

and Simulation

3. I What is a Flexible Manufacturing System?

3.2 Design of Flexible Manufacturing Systems

3.3 GRAI Methodology

3.3. I Analysis Phase

3.3. I. I Process Analysis

3.3. I. 2 Production Control Analysis

3.3.2 Design Phase

3.3.2.1 Detezadnation of the Part Selection and

Machining Process

3.3.2.2 Design Stage of Production Control System

3.3.2.3 The Use of SLmulation Techniques

4. The Control of Manufacturing Unit

4. I Scheduling

4. I. I Scheduling Problem

4. I. 2 Scheduling Problem Classification

4. I. 3 Scheduling Method

4. I. 3. I The Charts Method

4. I. 3.2 Serial Methods

4. I. 3.2. I Processing Time Rules

4.1.3.2.2 Due Dates Rules

4.1.3.2.3 Rules Independent of Processing Time and

of Due Date

4. I. 3.2.4 Composite Rules

4.1.3.3 Analytic Methods

4. 1.4 Conclusion

4.2 GRAI's Approach in Manufacturing Control

4.2. I Introduction

4.2.2 GRAI ' s Approach in Modelling

4.2.2.1 Structural _Model

4.2.2.2 Graphical Model

4.2.2.3 Logical Model

4.2.2.4 What Must be the Computerized Tool?

212

213

213

214

214

215

215

220

220

222

222

222

223

224

224

224

225

225

237

237

237

237

238

239

239

240

240

241

241

241

243

243

243

244

245

245

245

246

4.3

4.2.3 Control Module 246

4.2.3.1 Use of Control Modules 246

4.2.3.2 Specifications of the Control Module 247

4.2.4 Application of the Method 250

4.2.5 Conclusions 250

Artificial Intelligence Techniques in Control of Manufacturing Cell 251

4.3.1 The Scheduling Knowledge Based System: I.S.I.S.

4.3.2 S.R.L. Lan~_age 252

4.3.3 Constraint P~presentation 254

4.3.4 Constraint Directed Search 254

4.3.5 Conclusion 255

PART II: COMPUTATION A SUPPORT AND S O ~ FOR FMS, JUSTIFICATION

OF FMS, ROBOTICS, VISION, ASS~4BLY

Modular Computer Controls for Manufacturing Equipment

R. Dillmann

266

267

I. Hierarchical Computer Control Equilx~ent for Manufacturing Systems 267

I. I Introduction 267

1.2 Definition of Hierarchical Control System 268

I .3 Control Tasks of Each Level in the Hierarchy 269

I. 4 The Ccmaunication Network 271

1.5 Influence of VLSI Technology on Hierarchical Control Systems 273

I .5. I Minicc~puter for Higher Control Levels 274

I .5.2 Microcom~iter for Operational Control Levels 274

1.5.3 VLSI Interface Modules 276

1.5.4 Me/r~ry 277

1.5.5 VLSI Data Peripherals 277

I .5.6 Data Peripherals 279

1.6 Software and System Development Aids 279

2. Modular Design of Operational Control Level Units 296

2. I Introduction 296

2.2 Functional Definition of Operational Controls 296

2.3 Modular Structure of Operational Robot Control 297

3. Graphical ~ulation Techniques for Testing and Verification of Piece

Parts Handling Programs 309

3. I Introduction 309

3.2 Structure of the Robot Emulation System 309

3.3 Geometric Modelling 310

3.4 Generation of Motion Data 311

XIII

4.

3.5 Simulation of Interaction

3.6 Conclusion

Ad~ranced Computer Architectures (Sth Generation)

4. I Introduction

4.2 Cemponents of 5th-Generation Conlouters

4.3 Applications of 5th-Generation Cc~puters

4.4 Basic Software System and Progran~ing Languages

4.5 Computer Architecture of 5th-Generation Computer Systems

4.6 Conclusion

Quality Assurance and Machine Vision for Inspection

P. Levi

].

2.

Introduction

Quality Assurance: Functions r Problems and Realizations

2. I Quality Assurance Functions

2.2 Design of a Cc~puter Integrated QA System

2.3 Hierarchical ~mputer Systems for Quality Assurance

2.4 Architecture of a Data Acquisition System

2.5 Quality Assurance Methods

2.6 Measuring Methods for Quality Assurance

2.6. I Contact Measurement

2.6.2 Non-Contact Measurements

2.6.3 Manual Input

2.7 Cc~puter Languages for Test Applications

2.8 Implementation of a QA ~ter System

3. Machine Vision: Inspection Techniques, Mensuration

3. I Visual Inspection Tasks

3.2 Machine Vision Techniques for Inspection

3.2. I T~mplate-Matching

3.2.2 Decision-Theoretic Approach

3.2.3 Syntactical Approach

3.3 Automated Microscopic Material Testing

3.4 Laser Based Measurement and Inspection

3.4. I High Quantitative Mensuration

3.4.2 Semi Quantitative M~ns,~ration (Scanner)

3.5 Synthetical Images for Defect Classification

3.6 Robot Vision for Recognition and Sorting

3.6. I Interfacing of a Vision System with an Assembly Robot

3.6.2 Sorting of Castings

4. Peferences

and Robotics

311

312

321

321

321

322

322

323

324

329

329

33O

330

333

337

339

344

345

345

349

351

351

353

354

354

356

356

356

357

358

36O

36O

363

366

368

368

373

376

XIV

PROGRAMMING OF ROBOT SYSTEMS

Programning a Vision System

M. Cividini, G. Villa and M. Gini

I. Introduction

2. A Vision System for Industrial Applications

3. Logical Organization of GYPSY

4. LIVIA: The User Prograrmdng Language

5. Examples of LIVIA Programs

6. Conclusions and Acknowledgements

7. Bibliography

8. Appendix

Prograraning Languages for Manipulation and Vision in Industrial Robots

G. Gini and M. Gini

I. Introduction

2. How to Classify Robot Prograrmning Languages

3. Joint-Level Languages: The Example of MAL

4. Manipulator-Level Languages: Mathematical Foundations

5. Object Representation in Robot Programm/ng Languages

6. At the Object-Level: AL and Vision

7. Object and Task Levels: Problems

8. Conclusions

Towards Autcmatic Error Recovery J~i Robot Programs

M. Gini and G. Gini

I. Introduction

2. A Method for Automatic Error Recovery

2. I Dynamic Model

2. I. I Example

2.2 Semantics

2.2. I Examples

2.3 Knowledge Base

2.3. I Examples

2.4 Recovery Procedure

3. Concluding Remarks

4. References

378

378

378

379

380

381

384

386

386

387

389

389

392

394

397

401

404

407

408

411

411

412

413

413

413

414

414

414

415

415

416

XV

Design for Asse/nbly

A.H. Redford

417

I. Introduction 417

2. Design for Assembly Philosophy 419

3. Determination of the Most Appropriate Process 420

4. Re-Design for Manual Assembly 421

4.1 Classification and Coding for Handling and Insertion 421

4.2 Sequence of Design Analysis 423

4.3 Dete~nination of the Sequence of Assembly 426

4.4 Compilation of the Worksheet 426

4.5 Determination of Assembly Efficiency 428

4.6 The El~tion of Potentially Redundant Parts 428

4.7 Re-Design of High Cost Handling or Insertion Parts 429

5. Re-Design for Automatic Ass~Nbly 429

5. I Classification and Coding for Automatic Handling 429

5.2 Classification and Coding for Automatic Insertion 435

6. Robots in Manufacturing 443

7. Characteristics of Assembly Robots 444

8. Requirements for Robotic Assembly 445

8. I Faster Robots 445

8.2 Limited Capability, Cheap Robots 446

8.3 Versatile, Inexpensive Grippers 446

8.4 Identification of Assembling Families 448

8.5 Improved Assembly Efficiency 449

8.6 Low Cost Feeding 450

9. Classification and Coding for Automatic Parts Handling for

Flexible Assembly 450

10. Classification and Coding for Automatic Insertion for Flexible Assembly 451

11. Conclusions 452

Economic Analysis of Computer Integrated Manufacturing Systems

F.F. Leimkuhler

I. Introduction

2. Process Planning

3. Capacity Analysis Using CAN-Q

4. Capital and Labor l~equirements

5. Payback, Capital Cost, and Taxes

6. Cost Comparisons

7. System Efficiency

453

453

454

457

457

460

463

466

XVI

8. Justification of Automation Equipment

9. Sumaary

10. References

11. Appendix

Present State and Future Trends in the Develolxnent of Progr~g Languages

for ~nufacturing

U. Rembold and W. K. Epple

I. Introduction

II. Progran~ing of Machine Tools

I. The APT Language

2. The EXAPT Progranmdng System

3. Interactive Symbolic Progranming

4. Special Purpose Languages

5. Generative Progranming by the Machine Tool Control

III. Progran~dng languages for Robots

I. General Requirements for Progranmdng Languages for Robots

2. Programaing Methods for Robots

2. I Manual Programming

2.2 Programming with the Help of the Brake System of the Robot

2.3 Sequential Optical or Tactile Progranndng

2.4 Master Slave Prograrmning

2.. 5 Teach-in-Method

2.6 Textual Programming

2.7 Acoustic Progranming

2.8 Design Consideration for a High Order Language

3. A Survey of Existing Prograr~nJ~ng Languages

4. Concepts for New Prograrmfung Languages

5. Prograrmling with a Natural Language

6. Implicit Programming Languages

7. Programdng Aids

IV. Process Control

I. Extension of Existing Progranmaing Languages

2. PEARL - A Process and Experiment Autcmation Realtime language

3. ADA

4. Tools for the Development of Process Control Systems

V. Conm~rcial Data Processing

VI. Future Trends

P~_ferences

Figures

467

471

475

476

483

483

485

485

486

487

488

489

489

490

491

491

491

492

492

492

492

492

493

494

495

497

497

497

498

499

499

5O0

502

505

506

508

509