Advances in Automotive Production Technology – Towards Software-Defined Manufacturing and Resilient Supply Chains
Stuttgart Conference on Automotive Production (SCAP2022)
- Open Access
- 2023
- Open Access
- Book
- Editors
- Niklas Kiefl
- Frederik Wulle
- Clemens Ackermann
- Daniel Holder
- Book Series
- ARENA2036
- Publisher
- Springer International Publishing
About this book
This volume of the series ARENA2036 compiles the outcome of the 2nd Stuttgart Conference on Automotive Production (SCAP2022).
The peer-reviewed contributions in this book are arranged thematically in three parts and cover a wide variety of topics: (A) Software-defined Manufacturing, (B) Data-driven Technologies, and (C) Advanced Manufacturing and Sustainability.
SCAP2022 was organized by ARENA2036 in close collaboration with the Institute for Control Engineering of Machine Tools and Manufacturing Units of the University of Stuttgart. The Conference took place on site from November 16 - 18, 2022 and provided the opportunity for national and international scientists to present their latest research results.
The conference has taken another big step in becoming an established forum for topics related to the production of the future. The great success of this year's conference will be continued with the next SCAP in 2024 with new forward-looking topics.
This is an open access book.
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Table of Contents
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Part A: Software-Defined Manufacturing
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Frontmatter
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Real-Time Capable Architecture for Software-Defined Manufacturing
- Open Access
Download PDF-versionThe chapter delves into the transformative potential of Software-Defined Manufacturing (SDM), highlighting the need for a paradigm shift in production environments. It critically examines the limitations of traditional manufacturing systems and proposes a novel architecture inspired by IT practices. This architecture focuses on real-time network management and orchestration, enabling the flexible and adaptable deployment of automation applications. The chapter also introduces a conceptual framework for SDM, detailing how to define and integrate software-defined functionalities into higher-level systems. It emphasizes the importance of virtualization, hardware independence, and the use of standardized interfaces. The proposed solutions are designed to meet stringent quality of service (QoS) requirements for networking and computation, making the chapter a valuable resource for professionals seeking to enhance the reconfigurability and efficiency of automation systems.AI Generated
This summary of the content was generated with the help of AI.
AbstractProduction systems are characterized by static configurations and slow adaption to changing requirements. They no longer meet current trends in mutability and dynamic adaptation. Software-defined Manufacturing (SDM) like other software-defined approaches leverages abstraction of hardware to achieve higher flexibility. Based on abstracted hardware, software defines desired functionalities. Requirements from the Operational Technology (OT), especially determinism, must be combined with the flexibility and interoperability of Information Technology (IT). This paper proposes a stack that enables the implementation of SDM based on a requirements analysis. It covers the main phases of the life cycle of automation applications and additional requirements from SDM. We derive the necessary components while resorting to existing approaches whenever possible. Means for applications engineering, configuration, deployment, and orchestration, as well as execution at run time, are developed. -
Analysis of Real-Time Execution Models for Container-Based Control Applications
- Open Access
Download PDF-versionThe chapter delves into the analysis of real-time execution models for container-based control applications, highlighting the limitations of traditional monolithic architectures. It introduces modular control platforms using Microservices architecture, extending container-based control systems with event-based and cyclic execution models. These models are designed to meet the real-time requirements of control systems while supporting the dynamic reconfiguration of distributed control applications. The authors compare and analyze different scheduling methods, including global EDF and FPS, and present methods for minimizing intra-task interference. The chapter also includes a validation of the proposed models through a sample use-case, demonstrating their effectiveness in real-time performance. The innovative approaches discussed in this chapter offer valuable insights for professionals seeking to enhance the flexibility and efficiency of control systems in dynamic industrial environments.AI Generated
This summary of the content was generated with the help of AI.
AbstractSoftware-defined Manufacturing (SDM) aims to enhance the flexibility of production systems. Classical automation systems are not a suitable technological basis for SDM. While their hierarchical, rigid structures are increasingly being dissolved. Container-based virtualization, and modular software architectures, gain traction in automation systems. However, today’s PLCs are not a perfect fit for virtualization, as the control program still is a monolithic piece of software. We analyze cyclic and event-based real-time scheduling models for modular PLCs. Furthermore, techniques for reconfiguration at runtime are developed based on the selected execution models. -
Software-Defined Manufacturing for the Entire Life Cycle at Different Levels of Production
- Open Access
Download PDF-versionThe chapter delves into the concept of Software-Defined Manufacturing (SDM), a paradigm inspired by software-defined networking, aiming to decouple hardware from software to enhance flexibility and changeability in production systems. It discusses the challenges posed by the VUCA world and how progressive digitization can address these. The architecture proposed for SDM spans across all levels of production—from machines to global production networks—and throughout the entire production life cycle, from introduction to decline. The architecture leverages virtualization and abstraction to simplify planning and operation, using a service-oriented, modular approach. An exemplary use case illustrates how this architecture can facilitate the introduction of new product variants and optimize production systems in response to changing demands. The chapter concludes by highlighting the advantages of SDM and addressing the challenges that lie ahead in its implementation.AI Generated
This summary of the content was generated with the help of AI.
AbstractIncreasingly volatile markets, higher numbers of product variants and more sophisticated customer demands lead to a soaring complexity of productions themselves and their operations. An enabling technology that allows to cope with this increased complexity is digitization, as it enables data capturing and data driven analysis in production. Software-defined manufacturing (SDM) empowers to fully use the potential of digitization by decoupling physical production hardware and the associated control software. This enables an increase in the versatility of existing resources through automated generation of software for instantiations and interventions in production control. With the aim of enlarging the abstraction and decoupling capabilities of SDM, this paper presents a concept to use SDM at different abstraction levels of the production over the whole life cycle. The different abstraction levels, i.e. machine, production system and production network, are decoupled based on a service-oriented approach that defines interactions between these abstraction levels. The requirements to implement this approach are determined for the different levels where special notice is given to changing requirements over the life cycle of the production. With respect to the requirements, recommendations are given considering the integration of the concept in existing productions. Finally, potential benefits of this concept are discussed. -
Dynamic Safety Distance Determination for Human Robot Coexistence in Industrial Applications
- Open Access
Download PDF-versionThe chapter explores the critical topic of human-robot collaboration (HRC) in industrial settings, highlighting the necessity for flexible and adaptive safety functions. It delves into the challenges posed by traditional industrial robotic systems and the potential of collaborative robots, albeit limited by payload constraints. The main focus is on a novel approach to speed and separation monitoring (SSM) that dynamically calculates safety distances based on the real-time position and speed of both humans and robots. This method significantly reduces the required safety distances compared to traditional worst-case assumptions, optimizing space usage and enhancing overall manufacturing efficiency. The chapter includes detailed simulations and implementation strategies, showcasing the practical benefits of this innovative safety approach in industrial applications.AI Generated
This summary of the content was generated with the help of AI.
AbstractThe coexistence of humans and robots in manufacturing requires safety. Typically, safety functionalities for coexistence are based on speed and separation monitoring according to EN ISO 10218. Thereby, a robot should reduce speed or stop completely when an obstacle is too close to avoid collisions. Nowadays, despite this standard, speed and separation monitoring are still realized with static worst-case safety assumptions about the kinematics of humans and robots. Over the years, different static techniques have evolved in the industrial environment like fences, light fences, or camera-based systems where critical zones can be configured. The latter is admittedly more flexible in the configuration but still static during the run-time of the manufacturing system. The static worst-case assumptions result in large unnecessary distances between humans and robots, which leads to inefficient use of space. Therefore, factories are larger than they need to be, which leads to higher costs. This work aims to enhance the use of space in human-robot coexistence applications to make factory layouts more efficient. Therefore, a dynamic minimum distance calculation based on the DIN ISO 15066 with the kinematic information of the coexisting human and industrial robots is provided. It is shown in a simulation that this approach of a dynamic safety distance calculation leads to a reduction of the required space. -
Integrated Framework for Safety Management and Software-Assisted Safety Assessment in Fluid Production
- Open Access
Download PDF-versionThe document introduces the Fluid Production Safety 4A-Framework (FluPro-S4A), a novel approach to facilitate risk assessment and documentation in fluid production systems. It addresses the need for efficient and seamless production integration, focusing on the dynamic nature of modern manufacturing. The framework includes a modeling method for describing production assets and a four-step assessment process to ensure safety compliance. Key aspects include change acknowledgment, asset and system assessment, and approval assistance. The framework is designed to support safety engineers and production managers in adapting to rapid product changes, reducing manual efforts, and accelerating system commissioning. The case study demonstrates the practical application of the framework, showcasing its potential to minimize downtime and enhance safety management in fluid production environments.AI Generated
This summary of the content was generated with the help of AI.
AbstractIn the factory of the future, the concept of fluid production allows production processes to be adapted more frequently and efficiently to fulfill rapidly-changing product requirements and to prevail in an increasingly challenging market environment. Production resources, machinery and humans are integrated seamlessly to achieve common production goals. Rapid changes in system configurations are also enabled by highly modular, self-descriptive and reusable machinery modules called Mechatronic Objects. The high reconfigurability in fluid production poses new challenges for the safety management of future production systems. Every modification done to an existing system needs to be risk assessed and approved during the commissioning to allow its safety-compliant operation. As current industrial practices for risk assessment are still labor-intensive and time-consuming, new methods are needed to quickly integrate the aforementioned highly modular Mechatronic Objects into fluid production systems. In this paper, we propose a safety management and assessment framework to address the safety-related challenges for fluid production. This paper proposes a new modeling method to describe the different types of Mechatronic Objects and derives different stages for the assessment and approval of fluid production systems. This allows a more efficient and accelerated commissioning phase, a seamlessly integrated production and the reduction of manual efforts needed for the system commissioning. The proposed framework, the methods and the implemented software tools are validated using a case study for a highly reconfigurable assembly system at the research campus ARENA2036 at the University of Stuttgart.
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- Title
- Advances in Automotive Production Technology – Towards Software-Defined Manufacturing and Resilient Supply Chains
- Editors
-
Niklas Kiefl
Frederik Wulle
Clemens Ackermann
Daniel Holder
- Copyright Year
- 2023
- Publisher
- Springer International Publishing
- Electronic ISBN
- 978-3-031-27933-1
- Print ISBN
- 978-3-031-27932-4
- DOI
- https://doi.org/10.1007/978-3-031-27933-1
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