HIN – Project in i Computer Integrated Manufacturing...

HIN – Project in i Computer Integrated Manufacturing (CIM) Master of Science in Technology

NARVIK UNIVERSITY COLLEGE Telephone: 76 96 60 00

Title Developing PL/HIN within a CIM environment

Date 11.05.2006 Gradation: Open

Authors Ekaterina Tarakanova Espen Seljemo Magnus Bendiksen Kristian Knudsen

Amount of pages 34 Appendix 7

Department for IBDK

Major subject

Industrial Engineering

Supervisor Ziqiong Deng

Enterprise PL/HIN

Contact person -

Computer integrated manufacturing Exercise 1 11.05.06

Preface This is an exercise in the course STE 6156 Computer integrated manufacturing (CIM), spring year 2006. In order to get practical knowledge about this course the students have to implement a task to learn Computer Integrated Manufacturing and necessary software. The project counts 15 % of the final mark in this course. The report proposes how to develop and improve the Production Laboratory of Narvik University College (PL/HIN). The knowledge we have can help us in the future to apply the CIM- concept to any enterprise. To accomplish the task a system analysis of an AS-IS model have been made. To develop the function model we have used the IDEF0 method. In addition to this a mechanical resource model, computer system and a communication network resource designs for PL/HIN have been performed. Professor Ziqiong Deng is a supervisor of the project and lector in the Computer Integrated Manufacturing course.

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Contents Preface ....................................................................................................................................... 2 Contents...................................................................................................................................... 3 Introduction ................................................................................................................................ 4 1. Task .................................................................................................................................... 5

1.1 Requirement Definition for the development............................................................. 5 1.1.1 Requirements on education ................................................................................ 5 1.1.2 Requirements on R&D ....................................................................................... 5 1.1.3 Requirements on Industrial Services.................................................................. 5

1.2 Tasks of the project .................................................................................................... 6 2. AS-IS System analysis......................................................................................................... 7

2.1 AS-IS system.............................................................................................................. 7 2.2 Information Flow in the AS-IS system ...................................................................... 8

3. TO-BE system analysis..................................................................................................... 10 3.1 New equipment and systems in the TO-BE system ....................................................... 10 3.2 Layout of TO-BE system ............................................................................................... 12

3.2.1 TO-BE layout manufacturing area.......................................................................... 12 3.2.2 TO-BE system layout rapid prototyping room ........................................................ 14

3.3 Computer system (software) .......................................................................................... 14 4. Mechanical Resource model design ................................................................................. 15

4.1 Inventory List of AS-IS system...................................................................................... 15 4.2 New equipment and inventory in TO-BE system .......................................................... 15

5. The function model IDEF0 ............................................................................................... 16 Conclusion................................................................................................................................ 18 References ................................................................................................................................ 19 Appendix I. AS-IS and TO-BE system layout ........................................................................... 20 Appendix II. AS-IS system floor layout..................................................................................... 21 Appendix III. TO-BE system floor layout ................................................................................. 22 Appendix IV. IDEF0 Function model....................................................................................... 23Appendix V. Integrated System Level of AS-IS System…...….……………………………….32 Appendix VI. Integrated System Level of TO-BE…………...………………………………...33 Appendix VII. Comments on IDEF0 model…………………………………………….……..35

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Introduction

The Computer Integrated Manufacturing system models the manufacturing enterprise as coordinated workflows through a system of integrated automation and communications. Computer plays an enormous role in the 21st century.

The Production Laboratory of Narvik University College (PL/HIN) serves as a laboratory at the university level education. It was necessary to analyze the laboratory in order to develop the existing AS-IS system within a CIM environment.

First we gathered all the information about the AS-IS system. We divided the group into two, one part tried to improve the system, the other part made the preliminary design of the function model using IDEF0 method. This results in building of a new TO-BE system.

We have used the compendiums [1] “The Function Model of SAIL-1”, [3] “Developing SAIL-1 within a CIM environment”, [4] “Function Modeling using IDEF0”, [2].

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1. Task

1.1 Requirement Definition for the development

The requirements fall into following three categories: • Education • Research and Development (R&D) • Industrial Services

1.1.1 Requirements on education • To support graduate and undergraduate students education in the form of

laboratory experiments and final year diploma projects • To provide a CIM environment in which the students could investigate

problems and learn to solve these problems at machine and process level, cell level, and whole system level.

1.1.2 Requirements on R&D • To provide continuing inspiration for research ideas and "brain storming" of

new manufacturing concepts, theory and technology • To become a center of R&D for staff and research students at the individual

machine and process level and the integrated system level • In the integrated system level, the staff and research students can carry out

the related R&D projects such as in: (1) Cell level - Integration of machines into cells, cell control and monitoring,

material handling and tooling, simulation, logic cell concept and algorithm, etc.

(2) Shopfloor level - Scheduling, dispatching, control and monitoring of shopfloors, cell organizing and re-organizing, quality control, inventory control, etc.

(3) Factory (enterprise) level - Integration PL/HIN with MRP system, GT (Group Technology) and JIT (Just In Time) concept and application, quality management, CAD/CAP/CAM integration as well as integrating them with shopfloors/cells, concurrent engineering, lean production, intelligent manufacturing, etc.

(4) Inter-enterprises level - CALS (Computer Acquisitive Logistics Support), agile manufacturing, virtual manufacturing, global manufacturing, etc.

1.1.3 Requirements on Industrial Services • To promote the diffusion of concepts and technologies of flexible

manufacturing, computer integrated manufacturing, virtual manufacturing in local industries

• To conduct constant services and to foster the link with local industries • To accept and process the production orders coming from local industries or

other sources.

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1.2 Tasks of the project

According to the requirement definition above, we are asked to accomplish following tasks (refer to shading boxes of the figure followed):

System Implementation

System Analysis and

Preliminary Design

Detailed Design

Ag

Resource Model Design

for PL/HIN

Function Model Design

for PL/HIN

Information Model Design

for PL/HIN

Ag

Developing PL/HIN within a CIM Environment

• Doing system analysis and suggesting a CIM hierarchical control architecture of TO-BE system for PL/HIN (refer to [4] "Developing SAIL1 within a CIM Environment - The System Analysis and Preliminary Design Considerations"

• Doing preliminary design of TO-BE system on: - Function model design for PL/HIN.

(refer to [3]"The Function Model of SAIL1" but using only IDEF0 method) - Mechanical resource model design for PL/HIN.

- Computer system and communication network resource design for PL/HIN.

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2. AS-IS System analysis In this chapter an analysis of the AS-IS system is carried out to make the further improvements in the TO-BE system.

2.1 AS-IS system The production laboratory of HIN has installed: (1) Computer based manufacturing facilities, one flexible manufacturing cell which consists of:

• One CNC vertical machining center (Mori Seiki) • One industrial robot (ABB IRB 2000) for material handling.

(2) CAD/CAM system

• One Pro/Engineer CAD/CAM system for product design and NC programming

(3) Conventional general-purpose manufacturing facilities which consist of:

• One manually operated lathe: • One manually operated milling machine • One manually operated drilling machine • One manually operated grinding machine

(4) One manually operated coordinate measuring machine (5) Rapid prototyping facilities which consist of:

• One stereolithography machine (SLA 250) used for 3D part SLA-modeling • One vacuum casting machine (C001) used for duplication of SLA-models or

other purposes (6) One automated assembly cell which consists of:

• One industrial robot (Adept 604 - SCARA) used for handling of part assembly

• One camera vision device used for identifying parts • One part transporter/belt conveyer used for transporting parts into the

assembly cell

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The AS-IS system at PL/HIN uses to rooms, one for the workshop and one for rapid prototyping. These are shown in Figure 1.

Figure 1 AS-IS room usage

2.2 Information Flow in the AS-IS system The information flow or communication of AS-IS system in PL/HIN is described in Figure 2 and 3. The NUC server is the highest in the information hierarchy. It contains all the information in this system and is used as a gateway between the lower controls in the network.

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Figure 2 Information flow PL/HIN

The SCARA model is not connected to the NUC server. That’s because the system is so old that it can’t be connected. The SCARA system information flow is shown in Figure 3.

Figure 3 SCARA system information flow

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3. TO-BE system analysis The TO-BE system analysis describes what machines and software we want to install at the PL/HIN. The layout will also be changed to better support our CIM solutions.

3.1 New equipment and systems in the TO-BE system

• AGV train • 5 axis CNC machine • Water jet cutter • 3D laser scanning probe • Centralized PC control • Painting/ drying area

Automatic Guided Vehicle (AGV train): Used to transport products and material between the different manufacturing cells and storage facilities in the workshop. AGV can be manual or automatic controlled. We suggest using an AGV train in the workshop because it will give the students a possibility to test and use this kind of equipment and it will serve for industrial purposes.

[5]

Water jet cutter: A Water jet cutter is a tool capable of slicing into metal or other materials using a jet of water at high velocity and pressure, or a mixture of water and an abrasive substance. This machine is excellent doing cutting in 2D. It cuts very fast and the product gets a high surface finish. It is often used during fabrication or manufacture of parts for machinery and other devices. It has found applications in a diverse number of industries from mining to aerospace where it is used for operations such as cutting, shaping, carving, and reaming.

[6]

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5 axis CNC milling machine: 5 axis CNC milling machine gives more opportunities in milling different products that have complex and advanced shapes. A 5 axis CNC milling machine is the tool of choice to reduce set-up, eliminate multiple machine part transfer, produce sophisticated geometric shapes, create high tolerance features and differentiate the shop. Therefore it will be very useful for educational, research and industrial needs to have it.

[7]

X- ray machine Check and control welding seams if they have cracks or defects that can not be seen by a human eye. This can be very important in many structures and products that are welded.

[8]

3D laser scanning probe: Fast and easy scanning of 3D objects and translating the scanning to coordinates into a computer. It is accurate, automated, fast, and easy to use. They are available in a broad array of sizes. These systems offer the ultimate capabilities for scanning difficult shapes. This is a machine for PL/HIN which can satisfy any needs, especially in reverse engineering.

[9], [10]

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Painting/drying equipment: Surface painting of the manufactured products: This will give them a higher surface finish and to tolerate outer influences. Ex climate, weather conditions etc.

[11]

Centralized PC control: Is for centralized service supervision of the manufacturing area. The operator can control the different production cells that are connected to this PC. The PC control can also control the logistics of the stored materials and the manufactured products, machining times and operations.

[12]

3.2 Layout of TO-BE system The machines are collected together in different cells by the requirements mentioned above in the project. The layouts of AS-IS and TO-BE systems can be found in Appendices I-III.

3.2.1 TO-BE layout of manufacturing area Automatic production cell One automatic production cell with: Water jet cutter, 5 axis CNC milling machine, Takang turning machine and an ABB robot. The robot places a workpiece in the different machines and takes it out when the processing is finished. Then the workpiece goes to an assembly cell. Assembly cell SCARA robot takes the different parts from a buffer and assembles them together. These parts comes from the CNC milling machine, water jet cutter or Takang turning machine Machining cell In this cell an operator can machine small workpieces. Here it is only manual operated machines that are used.

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Control unit cell In our TO-BE system we have a cell control unit where an operator can control all the machines from one computer. The communication flow between this cell control and the machines can be LAN with Fieldbus and profibus and/ or RS-232 connection (see figure 4). Many old machines only have RS-232, but new machines can have LAN connection modules. The information flow goes from the cell control unit to different machines. In the cell control unit the operator can also control and watch the component flow in the manufacturing area, transportation from/to the machines, machining time at the different machines and so on. Then the operator can produce product with JIT philosophy. Control cell unit can be a centralized service supervision of the whole manufacturing area.

Figure 4 Fieldbus and Profibus connections between devices in a factory area [13].

Quality and scanning check cell The X-ray machine can perform a quality check of welding seams and look for crack formation in the welding seams. 3D laser scanning probe can read objects in 3D and translate these coordinates to a PC for further use, for example in reverse engineering. Painting / drying cell Painting of manufactured products gives a higher and better surface finish. Products with good quality and excellent finish will satisfy customers. In the drying compartment the painted products are dried after being painted. Logistics cell Storage has a place for finished goods and raw materials which are transported by AGV train between the different cells in the manufacturing area. Tool handling Tools must be placed in special cabinets and in a special order nearby the machines. If tools and equipment has been used they must be placed back on its original place. It is very important to keep a tidy manufacturing area.

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3.2.2 TO-BE system layout of rapid prototyping room The layout of the rapid prototyping room is the same as for the AS-IS system. The stereolithography machine and the surrounding machines for the prototyping process are located in the same room, because they do not have so many things in common with the manufacturing area. The stereolithography machine uses a laser and this machine must be placed on a stable surface with no vibrations. That is why we have placed these machines in a different room than the other manufacturing machines.

3.3 Computer system (software) A very important element in CIM is the computer software. This is the digital tools where the opportunities for making components almost are unlimited. We have listed up different programs for different manufacturing/production categories. Computer drawing/ simulation Pro Engineer 3D Design and Analysis program, mechanical drawing.

Generate G-Code to use in the milling CNC machine. Rhinoceros 3D Design program, mechanical drawing. Simulation Automod Draw a factory inventory and simulate different working

process inside this factory. Deneb Quest Deneb IGRIP Deneb Virtual NC

Virtual simulation programs for simulation of machines and equipment in shop floor, factories etc.

Measurement control National instruments LabView

Controlling and logging program of industrial processes. A lot of opportunities with this software to control units

Microsoft Visual studio.NET Make your own software programs and make a connection between software and hardware. Human machine interface.

Planning, technical drawing, mathematical simulation program Design IDEF Design function models on the PC.

habit Actrix Draw technical drawings, electronic forms, inventory forms, and so on.

Matlab Mathematical Program

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4. Mechanical Resource model design To reach ours requirements we need some new equipment in addition to the already existing equipment and machinery.

4.1 Inventory List of AS-IS system • Turning machine • Olio Kasto saw machine • Stamping machine • Milling machine • Sandblaster machine • MTS 647 Hydraulic wedge grip • Grinding machine • Material surface treatment • Ribon PL IR 500 • Finished product storage • Raw material storage • Takang CNC m/Fanuc TNC 200 ST • ABB IRB 2000 Robot • SCARA Adept Robot • ABB IRB 2000 controller • PC control unit • Welding machines

4.2 New equipment and inventory in TO-BE system • Finished product storage • AGV train • Water jet cutter • 5 axis CNC milling machine • Centralized PC control unit • Painting/ drying area • 3D laser scanning probe • X-ray welding check machine

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5. The function model IDEF0 To design the CIM-model for the PL/HIN we developed the function model using software IDEF0. An IDEF method is a representation of the activities and relationships between activities in an existing or planned system and provides both a process and a language for constructing a model of the decisions, actions, and activities in an organization. Basic modeling concepts of IDEF0: diagram, box, arrow, node tree, ICOM code and text. The diagrams are arranged hierarchal in levels. First level is called parent and the decomposed levels are children. The standard IDEF0 diagram is built up like shown in Figure 5. Where: Input

• Real objects or data needed to perform a function • Objects or data transformed by a function • Labeled with a noun or noun phrase

Output

• Objects or data produced as a result of the function • Labeled with a noun or noun phrase

Controls

• That which governs the accomplishment of the function • Things that influence or determine the outputs • Labeled with a noun or noun phrase

Mechanism

• Person, device, or data which carries out the function • The means by which the function is performed

CONTROL

INPUT FUNCTION

OUTPUT

MECHANISM

• Labeled with a noun or noun phrase

F

igure 5 IDEF0 Diagram standard

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Our A0 diagram includes the following main boxes: A1: Identify & Analyze System A2: Design New System A3: Implement New System A4: Evaluate New System This is the main areas that we based our model on. The A0 is a parent diagram, and from this children’s diagrams were decomposed. The complete model is shown in the Appendix IV.

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Conclusion According to the requirements and tasks of the project we have developed PL/HIN within a CIM environment in a way we think will satisfy the requirements. We have seen that it is of importance to install new and sophisticated equipment and system to be in the center of the world development to teach students and give them higher competences and experiences. To meet customer needs outside HIN it is necessary to have modern machines to manufacture advanced products with high quality and finish in a short time. Therefore it is also important to renew some machines and reorganize the manufacturing area in different cells. The Lab at HIN should improve and develop communication between machines and PC network. However to have an opportunity to buy such a systems HIN should utilize this equipment and produce or develop some products. The CIM concept is a necessary tool for high productivity enterprises in terms of high competition. The IDEF0 method gives a clear idea of the all functions and activities in a system. The function model helps to analyze and plan the system. --------------------- We have not considered the economical aspects of the project. The costs of buying new machinery and reorganization of the whole area of our TO-BE system are expensive. It is necessary to find out the payback of the capital investments to have a clear idea of equipment installation.

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References [1] Hartvigsen, G. (1998). Forskerhåndboken, Høyskoleforlaget [2] Function Modeling using IDEF0 [3] Shang, Y. (1993). The Function Model of SAIL-1, Research report [4] Deng, Z. (1993). Developing SAIL-1 within a CIM environment, Research report [5] AGV train, www.ie.ncsu.edu/.../ IndusTr/Images/Tow%20AGV.gif [6] http://www.flowcorp.com/ [7] http://www.moriseiki.com/english/index.html[8] http://www.aqts.com/weldingtech.htm [9] http://www.esrf.fr/conferences/proceedings/IWAA99/PAPERS/CSchn99.pdf[10] http://www.laserdesign.com/ds_series.htm[11] http://www.atlantictechcenter.com/atc/DayCourses/AutomotiveTechnology/[12] http://www.mamut.com/homepages/Norway/1/18/Molteberg_inst/subdet4.htm[13] Fieldbus- profibus http://www.apv.com/NR/rdonlyres/B8E18AD4-7F2E-4F8C-8DB2-7EF1166F19AB/0/fieldbus.gif

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http://www.flowcorp.com/

http://www.moriseiki.com/english/index.html

http://www.aqts.com/weldingtech.htm

http://www.esrf.fr/conferences/proceedings/IWAA99/PAPERS/CSchn99.pdf

http://www.laserdesign.com/ds_series.htm

http://www.atlantictechcenter.com/atc/DayCourses/AutomotiveTechnology/

http://www.mamut.com/homepages/Norway/1/18/Molteberg_inst/subdet4.htm

http://www.apv.com/NR/rdonlyres/B8E18AD4-7F2E-4F8C-8DB2-7EF1166F19AB/0/fieldbus.gif

http://www.apv.com/NR/rdonlyres/B8E18AD4-7F2E-4F8C-8DB2-7EF1166F19AB/0/fieldbus.gif


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Appendix I. AS-IS and TO-BE system layout

SLA 250

Storage

PC control unitPerleugle

Storage

Rapid prototyping material treatment

areaProduct washer

Heatingmoulding

mass Rapid prototyping material treatment

area

PCA Post

CutingApparature

AS-IS and TO-BE system layouts of rapid prototyping room

Operator "Tony"

Harden moulding

mass products

Vacum casting machine

Storage


Appendix II. AS-IS system floor layout

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Appendix III. TO-BE system floor layout

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Appendix IV. IDEF0 Function model

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Comments “Gruppen“ is written

in Norwegian

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Computer integrated manufacturing Exercise 1 11.05.06 Computer integrated manufacturing Exercise 1 11.05.06

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Computer integrated manufacturing Exercise 1 11.05.06 Computer integrated manufacturing Exercise 1 11.05.06

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Comments Available machines

and software on

marked were added

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Comments Logistics methods

were added


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Comments Design Quality Control box was added


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Comments Group was

changed with IT

Department


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Comments Group was

changed with

Installation Engineers

Appendix V. Integrated System Level of AS-IS System


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AS-ISsystem Factory

NUC Shopflor

PL/NUC Cell

Equipment

Workstation

Computer based manufacturing

Conventional general - purpose

manufacturing

Measuring

Rapid prototyping

Automated assembly

Industrial robot (ABB IRB 2000)

Manually operated lathe + CNC lathe EMCO compact 6P-CNC

Manually operated milling machine

Manually operated drilling machine

Manually operated grinding machine

Manually operated coordinate measuring machine

Different kinds of manual measuring equipment

Stereolito-graphy machine (SLA 250)

Vacuum casting machine (C001)

Industrial robot (Adept 604 – SCARA)

Camera vision device

Transporter/belt conveyer

Parts L/UL eqpt or human











Tools L/UL eqpt or human















CNC vertical machining center (Mori Seiki)


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TO-BE system Factory Appendix VI. Integrated

System Level of TO-BE NUC

Shopflor

PL/NUC Cell

Workstation

Equipment

Computer based

manufacturin

Automated assembly

Industrial robot (ABB IRB 2000)

5 – axis CNC milling machine

Water- jet cutter

Industrial robot (Adept 604 – SCARA)

Camera vision device











Transporter/belt conveyer

Conventional general - purpose

manufacturing

Manually operated lathe + CNC lathe EMCO compact 6P-CNC

Manually operated milling machine

Manually operated drilling machine

Manually operated grinding machine




Material transport

AGV train












CNC vertical machining center (Mori Seiki)

Computer integrated manufacturing Exercise 1 11.05.06 TO-BE system

Factory

NUC Shopflor

PL/NUC

Workstation

Cell

Equipment

Measuring

Rapid prototyping

Manually operated coordinate measuring machine

Different kinds of manual measuring equipment

Stereolito-graphy machine (SLA 250)

Vacuum casting machine (C001)

Parts L/UL

Parts L/UL

Parts L/UL

Parts L/UL

3D lazer recorder probe

Material quality control

X-ray machine

Parts L/UL

Parts L/UL

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eqpt or human

eqpt or human

eqpt or human

eqpt or human





eqpt or human


eqpt or human


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