Chapter 6 computer and controls systems within manufacturing

Data Communication & Networking in
Manufacturing System
N. A. Sutisna
PLM Consultant, IBM Indonesia
Lecturer, President University

Chapter 6
Computers and Control
Systems within
Manufacturing
Chapter 6
Computers and Control
Systems within
Manufacturing

The Range and Scope of Computers within
Manufacturing
The Range and Scope of Computers within
Manufacturing
Within any modern manufacturing organisation, computers may
be used at a number of different levels, including:
• Management / Financial Information Systems
• Production and Inventory Control / MRP / MRPII
• Software Simulation
• Computer Aided Process Planning
• Computer Aided Design and Drafting
• Control of Automated Mechanisms (Programmable Logic)
• Data-acquisition
• Machine Control Systems (Computer Numerical Control)
• Robot Control
• Continuous Chemical Process Control
• Production Line Control (In-line Transfer Machines)
• Flexible Manufacturing System Control.

Computer applications is used to share data (or databases) that is of
crucial importance to manufacturing, in order to:
• minimise times between work orders and production
• minimise inventory and stock levels
• minimise bottle-necking of parts / products in plant
• minimise production / product costs
• minimise design errors and transmission of design errors
• minimise overall response times to changing market demands
• maximise equipment utilisation
• maximise product consistency and quality
• maximise flexibility of production equipment
• prevent unnecessary (repetitive) human entry of data.

Programmable Logic ControllersProgrammable Logic Controllers
Programmable Logic Controllers (PLCs) are perhaps the most prolific
of all modern industrial control systems. They are used for a wide
range of applications and are very diverse in their capabilities
Traditional workstations, PCs and mini-computers are still a more
suitable platform on which to perform large calculations than the
PLCs.  computer to do the "numbercrunching“ while a PLC does
the data-acquisition

The criteria typically used to select a PLCThe criteria typically used to select a PLC
• PLC Programming Language
• Number of Inputs and Outputs (I/O capability)
• Expansion Capability
• Processor Execution Speed
• Modularity of Design
• Ruggedness of Design
• Capacity for Integration with other systems through:
• Serial Communication
• Back-plane (Bus) Communication
• Local Area Network Communication.

Multiple Axis Motion Controllers (CNC and
Robotics)
Multiple Axis Motion Controllers (CNC and
Robotics)
Many machines and devices within manufacturing consist of little
more than a number of servo-motor driven axes, which are used to
either position an end-effector (tool) or a work-piece so that the
work-piece can be either moved, machined or processed.

CNC systems and robot controllers generally come with built-in
PLCs, usually of specialized and complementary design. The PLCs
are integrated into the CNC or robot control system, under the
control of the main processor.

Interlocking CNC Machines to RobotInterlocking CNC Machines to Robot

Linking Computer Aided Design to
Manufacture
Linking Computer Aided Design to
Manufacture
File transfers between host computers and CNCs are now most
commonly performed through a (serial) data communications
link

Data Transmission ProblemData Transmission Problem
Problems due to corrupted program files may not always be
conspicuous or easy to trace until it is too late.
For these reasons, we need to:
1. Minimize errors occurring during transmission
2. Provide a mechanism for detecting errors
3. Check all incoming data
4. Detect and/or correct any corrupt information through re-
transmission procedures.

Ways to tackle transmission problemsWays to tackle transmission problems
The first objective can most readily be achieved by selecting an
appropriate communications "medium" in which noise and EMI are
minimized. Although shielded, "twisted-pair" cables and co-axial
cables are commonly used as communications media, they are both
susceptible to Electro-Magnetic Interference (EMI).
Optic fibre systems, which use light pulses rather than electrical
signals for transmission, are now a preferred alternative, since they
are immune from EMI.
Objectives 1 to 4 can all be realized by establishing a set of rules by
which both the receiving and transmitting devices can check and
correct for errors in data transmission.
This set of rules is referred to as a "communications protocol". Most
modern computer systems can be programmed to respond to any
protocol.
However, we again note that many CNC machine controllers do not
have this programming flexibility. CNC manufacturers often equip
their controllers with built-in communications protocol software
(DNC) to perform this task.

Manufacturing SystemsManufacturing Systems

Dedicated In-line Transfer MachineDedicated In-line Transfer Machine
The dedicated, in-line transfer machine is shown is a high volume,
low part variety system. It is composed of a number of machining
stations and a transfer conveyor. Each of the machining stations is
designed and tooled for a specific application.
These machining modules are generally not user-programmable devices. They are pre-
programmed to perform only a fixed task.

Hard Wired InterlockingHard Wired Interlocking
The hard-wire, inter-locking, communications techniques, shown
in Figure 2.9, for dedicated systems are generally adequate
because:
• individual machining modules are relatively simple devices,
executing simple, fixed, programs
• the amount of information which any, one machine can feed
back to a supervisor is comprised of little more than off/on
limit-switch status
• the supervisory controller does not need to change programs
on individual modules in the system.

Flexible Manufacturing SystemFlexible Manufacturing System
The Flexible Manufacturing System (FMS), designed for a very
wide variety of parts. The intelligence level of each module
(machine) within the system is much greater than that within the
dedicated production line

FMS Controller FunctionsFMS Controller Functions
In a complex FMS environment, where a number of different
part-types may be within the system simultaneously, the
controller is required to:
• co-ordinate the flow of work-pieces of differing types, from
one machine to another, based upon a rolling schedule
• activate different part programs on CNC machines, as
required by the part-types present in the system
• down-load part programs to CNC machines as required by
the machines
• co-ordinate (inter-lock) the role of the work-piece
transport system with the operation of CNC machines.
Hard-wire communications do not provide an adequate means
of conveying complex status information from a machine
controller to a system control computer.
This can only be achieved through more sophisticated data
communications techniques.

Key Technology of Digital
Manufacturing
Key Technology of Digital
Manufacturing

Key Technology of Digital ManufacturingKey Technology of Digital Manufacturing
This Chapter will discuss the key technologies of digital
manufacturing science from five aspects, including:
 various digital technologies in the product lifecycle
 resources and environment technology facing digital
manufacture
 management technology in digital manufacturing process
and system
 control technology in digital manufacture
 digital recognition and integration technology in products,
binding the key characteristic of digital manufacturing
science’s development.

Various Digital Technologies in Product LifecycleVarious Digital Technologies in Product Lifecycle
CAD/CAE/CAPP/CAM and Integrated Modeling of CAx System
With the development of network technology and information
technology as well as the exchanging and sharing between
multimedia visual environment technology, product data
management (PDM) system, distributed cooperative design and
cross-platform, cross-regional, synchronous and asynchronous
information, group collaboration and intelligent design between
multi-enterprises, multi-teams, multi-people and multi-applications
have obtained deeper research and entered practical stage.

Digital Equipment and Digital Processing Technology
Various Digital Technologies in Product Lifecycle
Digital Equipment Technology:
Typical digital devices include numerically-controlled machine
tool, machining center, industrial robots, digital measurement
and detection devices, rapid prototyping devices and so on.
1. Digitized modeling of equipment
2. Digital equipment’s networking

Digital Processing Technology
Fig. 8.3 The composition of digital processing

The Technology of Digital Maintenance and Diagnosis
Fig. 8.5 The key technology of product digital maintenance

Fig. 8.7 The Function of Remote Failure diagnosis system
The Technology of Digital Maintenance and Diagnosis

The key technologies of digital logistics:
 Logistic informatization: Related technology includes bar
code technology, network communication technology,
database technology, electronic commerce technology,
enterprise resource planning, etc
 Logistic intelligence: It refers to using intelligent integrated
technology, making logistic system have the ability of
thinking, perception and reasoning judgment, thus resolving
the problems in logistic operation
 Logistic Virtualization: It refers to the description and
expression on essence of actual logistic process. Its
foundation is to use computer emulation and virtual reality
technology to express, model and emulate all effective
logistic behavior and factors, and to depend on group
cooperative work on computer to establish 3D full-digital
model of the whole logistic process, in order to realize the
analysis and evaluation of logistic process in logistics design
stage

Key Technology of Digital Logistics
Fig. 8.8 The structure of digital logistic system

Digital Logistic Supporting System
 Digital logistic management platform: The platform realizes the
logistic operating digitalization between enterprise interior,
alliance partner and customer, which carries out intelligent and
digital management (DM) to enterprise logistic process
 Warehouse management system: The system improves
traditional warehouse enterprise and carries out effective
management and disposal to goods. Realizing the
electronization of warehousing work flow is the most important
function of the system
 Transportation management system: The system is the logistic
transportation management software which is designed by an
overall measurement, analysis and standard haulage operation
process and the use of modern logistic management method
based on network environment.
 Distribution management system: This system has functions on
delivery of central work flow as well as logistic management

Resource and Environment Technology in
Digital Manufacture
Digital Manufacture
The Sharing of Digital Manufacture Science
The manufacturing resource information sharing based on STEP
Resource Organization and Management Technology

Digital Manufacture
Digital Manufacture
The manufacturing resource information sharing based on
network
Resource Organization and Management Technology

Digital Manufacture
Digital Manufacture
The product information integration base on XML
The Integration of Digital Manufacturing Resource

Digital Manufacture
Digital Manufacture
PDM system and its integration
The Integration of Digital Manufacturing Resource
At present, the integration patterns between PDM and ERP mainly have the
following three kinds:
•The package integration of application system. The application tools
access data document with corresponding format from PDM system, which
is called encapsulation
•The two-way transmission of document. With the effort of PDM and ERP
system’s developer, nowadays the most advanced PDM system carries on
seamless two-way transmission between product data and related
document data as well as ERP system
•Through mode. It is very effective to integrate independent PDM and ERP
system through file transfer, which contradicts the principle that data must
be stored in the same location to keep all documents clear and avoid data
inconsistency. Because the bottom layers of PDM and ERP systems are all
relational databases, and the data about product is stored in each domain,
the so-called through mode is that the two systems directly carry on
operation to the data of database and exchange data.

Manufacturing Grid: the Management and Scheduling of
Resources
Digital Manufacture
Manufacturing grid is a kind of specific materialized form of modern
integrated manufacturing and agile manufacturing mode in global
and networked economic environment.
Its approach is to use grid technology, information technology and
computer and advanced management technology, in order to
overcome the obstacles which the distance in the space brings and
achieves the connectivity of all of the geographically dispersed
manufacturing resources through grid

Digital Manufacture
The Architecture of Manufacturing Grid

The Prototype System of Manufacturing Grid
Digital Manufacture

Management Technology in the Digital Manufacturing
Process and System
Process and System
The Digital Resource Management System ERP in Digital
Manufacturing
ERP is the most effective mode to realize the DM of enterprise. First of all
ERP is a DM concept; secondly ERP is a practical management tool. Its
effect is realized based on the following aspects in the enterprise
manufacturing process.
Implementation of ERP system in enterprise, which realizes the essential
conversion of production manufacturing management model in enterprise
through implementation of advanced management modes such as MRP, JIT
and PDM.
We use CIMS thought to complete the integration through the CAD/CAM,
CAPP, MAS (manufacturing automatic system), CAQ (computer-aided
quality) of PDM (product data management) and TIS (technology
information system), making the digital design of product integrate with
digital manufacturing

Suppliers/
Vendor
• Supplier chain
• Purchasing
Customer Support
• Pre/Post Sales Support
ISO Approval
Review,
Design Release
• Digital Design Review
• View & Markup
• Recognition
• Audit
Account / Finance
• Costing
• Define
incentiv
e
program
Sales &
Marketing
• Quick Response
• Marketing Proposal
• Easy to quote
• Presentation
• Product Launch
Human
Resource
• Training
• Corporate Communication
• Staff Development
• Virtual Learning
Engineering
Design
• CAD/CAM
• CAE / FEA
• Prototyping
IT Research &
Development
• Technology
• Methodology
• Integrating
Distribution
• Fulfillment
• Delivery
Manufacturing/
Assembly
Shop floor
• Product Assembly/
Disassembly Sequencing
• Robotic/Work Cell Animation
• Digital Factory
Factory Manager/
Production
Planner
• Actual vs. schedule
• Scheduling
• Work-to-lists
• Route cards
Quality Control
• Defect Analysis
• Quality Control
e-Manufacturing BOM
P L M
Process and System
Process and System

The Property Right Protection of Network Manufacturing
Product Based on Digital Watermarking Technology
The Property Right Protection of Network Manufacturing
Product Based on Digital Watermarking Technology

Control Technology in Digital ManufactureControl Technology in Digital Manufacture
1. Networked Control System

2. Virtual NC Technology

3. The Embedded Control Technology

Digital Recognition and Integration Technology in
Product
Product
Radio-Frequency Identification Technology
Bar Code Recognition Technology
Electromechanical Integration Technology and the Light
Mechanical and Electrical Integration Technology
The Electromechanical Integration Technology
The Light Mechanical and Electrical Integration Technology

Product

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