IEC (International Electrotechnical Commission) is the authority that publishes different standards in the  fields  of  electrical  and  electronics  engineering,  to  be  used  internationally.  In  the  area  of manufacturing, it has demanded a new standard to fulfil better solutions of dynamic requirements. The  IEC  61499  redacted  by  IEC  offers  interoperability,  portability,  configurability  and  distributed control applications for manufacturing processes. However, this standard is not a replacement of IEC 61131-3,  one  of  the  most  used  standards  in  industry;  instead,  it  is  a  complement  of  it.  The  basic software units of IEC 61499 are named Function Blocks (FBs), which can be described as blocks that encapsulate functionality. By combining FBs together, it is possible to solve complex problems.   The  objective  of  this  project  (in  close  cooperation  with  another  project)  is  to  develop  a  software environment in Java language. It follows the requirements of IEC 61499, and implement a Function Block  designer  and  a  runtime  execution  environment,  as  a  part  of  an  existing  Wise-ShopFloor framework. The scope of this project covers:     FB  algorithm  editor:  Each  FB  has  one  or  more  algorithms,  which  can  be  defined  in  the algorithm editor using IEC 61131-3 or Java.     FB serialization: Opening and saving the configuration of FBs in Java Class file is one of the tasks  of  this  project.  As  soon  as  the  configuration  is  saved,  the  Java  code  of  FB  can  be generated. Java code is generated because compiled Java allows execution of FB. Saving in Java  Class  file  permits  portability,  i.e.  the  saved  configuration  can  be  opened  in  any  JVM system, and vice versa.      Case study: A simulation of an assembly station using an ABB IRB 140 robot is studied and implemented using the runtime simulator of the Java platform, in which some basic FBs have been also created in a library. This project also includes: (1) implementation of user interface and (2) FB serialization in XML. It  is  anticipated  that  the  developed  environment  will  be  able  to  save  and  open  FBs  configurations either in XML or in Java Class, following the specification of IEC 61499. It will allow portability and reusability.  Because  of  the  portability,  the  so-designed  FBs  can  be  validated  using  another  FB environment such as FBDK (Function Block Development Kit).

The purpose of this project is the creation of an adaptive Function Block control system, and the implementation of Artificial Intelligence integrated within the Function Block control system, using IEC 61499 standard to control an ABB 6-axis virtual robot, simulated in the software RobotStudio. To develop these objectives, we studied a lot of necessary concepts and how to use three different softwares. To learn how to use the softwares, some tests were carried out. RobotStudio is a program developed by ABB Robotics Company where an ABB robot and a station are simulated. There, we designed and created a virtual assembly cell with the virtual IRB140 robot and the necessary pieces to simulate the system. To control the robot and the direct access to the different tools of RobotStudio, it is necessary to use an application programming interface (API) developed by ABB Robotics Company. C sharp (C#) language is used to program using the API, but this language is not supported by the Function Block programming software nxtStudio. Because of this, we used VisualStudio software. In this software, we use the API libraries to start and stop the robot and load a RAPID file in the controller. In a RAPID file the instructions that the robot must follow are written. So, we had to learn about how to program in C# language and how to use VisualStudio software. Also, to learn about IEC 61499 standard it was necessary to read some books. This standard determines how an application should be programmed through function blocks. A function block is a unit of program with a certain functionality which contains data and variables that can be manipulated in the same function block by several algorithms. To program in this standard we learnt how to use nxtStudio software, consuming a lot of time because the program is quite complex and it is not much used in the industrial world yet. Some tests were performed to learn different programing skills in this standard, such as how to use UDP communication protocol and how to program interfaces. Learning UDP communication was really useful because it is necessary for communication between nxtStudio and other programs, and also learning how to use interfaces to let the user access the program. Once we had learnt about how to use and program the different softwares and languages, we began to program the project. Then, we had some troubles with nxtStudio because strings longer than fourteen characters cannot be used here. So, a motion alarm was developed in VisualStudio program. And another important limitation of nxtStudio is that C++ language cannot be used. Therefore, the creation of an Artificial Intelligence system was not possible. So, we created a Function Block control system. This system is a logistical system realised through loops, conditions and counters. All this makes the robot more adaptive. As the AI could not be carried out because of the different limitations, we theoretically designed the AI system. It will be possible to implement the AI when the limitations and the problems are solved.

Program slicing has been used as a way to improve the efficiency of debugging and program analysis. Nowadays, automated test generation is being used to create tests automatically by analysing the program structure and suggesting necessary tests. This kind of techniques are prone to efficiency problems when applied to large programs containing many lines of code. This is especially true for software in industrial practice, such as the ones running on Programmable logic controllers (PLC) that are used in a wide variety of tasks from toys to avionics and rail transport. Function Block Diagram (FBD) is a language used for programming PLCs that has gained lots of attention in industrial practice due to its graphical nature. These FBD programs are often used in real time and safety critical systems, and these systems require extensive testing in order to prove that they pass safety requirements of their respective domains. In order to improve the efficiency of applying automated test generation on FBD programs we propose two FBD program slicing algorithms based on the structure of these diagrams and how they are programmed. These FBD program slicing algorithms are applied on several industrial programs for PLCs in order to evaluate their feasibility and what effect slicing has on test generation. Six FBD programs were selected out of 189 provided by Bombardier Transportation Sweden AB. The six programs were sliced according to these FBD slicing algorithms and then evaluated in terms of efficiency and applicability. Our results suggest that slicing can be used to reduce the needed generation time and memory usage required for automated test generation. However, our observations show that slicing can also increase the number of test cases generated and how this test cases are merged into one test suite for the entire program.

An Adaptive Reconfigurable Manufacturing System for maintenance of structural parts and functionality of the autonomous vehicle with IEC61499 standard is proposed. Using the ABB RobotStudio, the functionalities of the IRC5 is programmed with PC interface. nxtStudio from nxt Control company is used as development and runtime function block control system which is been deployed into EV3 Lego (Autonomous vehicle). This FB will generate the control signal which in turn initiates the functionalities of the ABB IRC5. This control signal is transferred through TCP /IP socket communication between Robotstudio and nxtStudio. This also includes the hardware implementation of the assigned task.

Made available in DSpace on 2016-12-12T17:38:31Z (GMT). No. of bitstreams: 1 Eduardo Harbs.pdf: 12792734 bytes, checksum: b505810b68894ae2924a805e7f89d032 (MD5) Previous issue date: 2012-10-09 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The industry has found difficulties towards CNC machines flexibility, due to the CNC programming current standard, the ISO 6983 or G/M code. The ISO 14649 or STEP-NC was developed to replace the current standard. It is a new unified data transfer model between CAD/CAM and CNC systems. To satisfy the new automation and control systems requirements, the IEC 61499 standard was developed, aiming the use of software objects, called function blocks (FBs). In this work, the standards STEP-NC and IEC 61499 were integrated to build a new generation of CNC, where STEP-NC supplies the complete data model without functionality, and the FBs provide the functionalities to the data model for the machine tool command. In this context, a controller for a CNC machine prototype, compliant to STEP-NC and IEC 61499 standards was developed. The prototype consists of a 2,5D milling machine, driven by a group of three servomotors drivers with integrated PLCs. A set of software was developed for compiling STEP-NC files and the automatic generation of IEC 61499 models, viewing, editing and executing FBs and FB networks, and further a library with IEC 61499 models. Test on software and prototype was performed machining an example workpiece, achieving the proposed goal and providing the individual characteristics of the standards in the controller, such as: interoperability, portability, use of features, configurability, distribution and adaptability. / A indústria tem enfrentado dificuldades quanto à flexibilidade das máquinas CNC, devido à norma utilizada atualmente para a programação CNC, a ISO 6983 ou código G/M. Com objetivo de substituição desta norma, desenvolveu-se a ISO 14649 ou STEP-NC, que é um novo modelo de transferência de dados unificado entre sistemas CAD/CAM e CNC. Para atender os novos requisitos de automação e controle de sistemas, desenvolveu-se a norma IEC 61499, visando o uso de objetos de software, os function blocks (FBs). Neste trabalho integraram-se as normas STEP-NC e IEC 61499 para a construção de uma nova geração de CNCs, onde STEP-NC fornece o modelo de dados completo, porém sem funcionalidade, e os FBs fornecem as funcionalidades ao modelo de dados para o controle da máquina-ferramenta. Para tal, foi desenvolvido um controlador para uma máquina CNC protótipo aderente às normas STEP-NC e IEC 61499. Este protótipo é constituído de uma fresadora 2,5D, acionada por um conjunto de três servoacionamentos com CLPs integrados. Um conjunto de software foi desenvolvido para compilação do arquivo STEP-NC e geração automática de modelos IEC 61499, visualização, edição e execução de FBs e rede de FBs além de uma biblioteca de modelos IEC 61499. Teste do software e do protótipo foi realizado com a usinagem de uma peça exemplo, alcançando o objetivo proposto e provendo as características individuais das normas no controlador, como: interoperabilidade, portabilidade, uso de features, configurabilidade, distribuição e adaptabilidade.

Orientador: Nunzio Marco Torrisi / Dissertação (mestrado) - Universidade Federal do ABC, Programa de Pós-Graduação em Engenharia da Informação, 2012

Zur einfacheren Entwicklung von technischen Systemen werden heutzutage vielfach funktionsblockorientierte Modellierungssprachen wie MATLAB/Simulink verwendet, die ein System als Netzwerk von miteinander verbundenen Funktionsblöcken darstellen. Aufgrund wechselnder Anforderungen entstehen dabei viele Modellvarianten, die nicht mehr effizient verwaltet werden können. Eine Lösung hierfür ist der Einsatz von Produktlinien, bei dem alle Varianten zusammengefasst und in wiederverwendbare Bestandteile zerlegt werden. Die Einzelvarianten werden dabei nur noch bei Bedarf aus diesen Bestandteilen zusammengesetzt. Die Erstellung dieser Produktlinien ist jedoch mit hohem manuellen Aufwand verbunden, besonders wenn vorhandene Modelle wiederverwendet werden sollen. Dies verhindert oft die Einführung dieses Paradigmas. Das Ziel der Dissertation war es deshalb, diese Migration vorhandener Modellvarianten und damit die Erstellung der Produktlinien zu automatisieren. Hierzu wurde eine Migrationsschrittfolge vorgeschlagen: Mithilfe eines Model-Matching-Ansatzes werden zuerst Gemeinsamkeiten und Unterschiede zwischen den Modellen identifiziert und daraus ein zusammengefasstes Modell und sogenannte Features abgeleitet. Mithilfe der Formalen Begriffsanalyse werden daraufhin die Abhängigkeiten zwischen diesen Features extrahiert und daraus ein Feature-Modell erstellt. Feature-Modell und zusammengefasstes Modell bilden dabei eine Produktlinie, die exakt die vorgegebenen Modellvarianten beschreibt.

This thesis describes the design and implementation of control applications for the deposition interface and mass spectrometer. The paper describes the working principle of these devices and their hardware specifications. It also describes how the design and the conception of the application. Developed applications are tested on real devices at the end.

Zur einfacheren Entwicklung von technischen Systemen werden heutzutage vielfach funktionsblockorientierte Modellierungssprachen wie MATLAB/Simulink verwendet, die ein System als Netzwerk von miteinander verbundenen Funktionsblöcken darstellen. Aufgrund wechselnder Anforderungen entstehen dabei viele Modellvarianten, die nicht mehr effizient verwaltet werden können. Eine Lösung hierfür ist der Einsatz von Produktlinien, bei dem alle Varianten zusammengefasst und in wiederverwendbare Bestandteile zerlegt werden. Die Einzelvarianten werden dabei nur noch bei Bedarf aus diesen Bestandteilen zusammengesetzt. Die Erstellung dieser Produktlinien ist jedoch mit hohem manuellen Aufwand verbunden, besonders wenn vorhandene Modelle wiederverwendet werden sollen. Dies verhindert oft die Einführung dieses Paradigmas. Das Ziel der Dissertation war es deshalb, diese Migration vorhandener Modellvarianten und damit die Erstellung der Produktlinien zu automatisieren. Hierzu wurde eine Migrationsschrittfolge vorgeschlagen: Mithilfe eines Model-Matching-Ansatzes werden zuerst Gemeinsamkeiten und Unterschiede zwischen den Modellen identifiziert und daraus ein zusammengefasstes Modell und sogenannte Features abgeleitet. Mithilfe der Formalen Begriffsanalyse werden daraufhin die Abhängigkeiten zwischen diesen Features extrahiert und daraus ein Feature-Modell erstellt. Feature-Modell und zusammengefasstes Modell bilden dabei eine Produktlinie, die exakt die vorgegebenen Modellvarianten beschreibt.

Detta arbete var beställt av Sjöfartshögskolan i Kalmar. Skolan ville ha en enhet som kunde mäta aktiv-, reaktiv- och skenbar effekt, ström, spänning, frekvens och cosϕ på en generator och som kommunicerade vidare dessa värden till en PLC. Detta för att kunna lastfördela lasten mellan ett antal generatorer i kursen Tillämpad elteknik 15 hp där studenterna bygger en generatorinstallation med tre generatorer. Ett funktionsblock för lastfördelning skulle också programmeras. Prototypen som konstruerades baserades på en Arduino Ethernet och kommunikationen löstes med Modbus TCP/IP över Ethernet. Ett lastfördelningsprogram programmerades i form av ett funktionsblock som studenterna kunde importera till CoDeSys v2.3 och använda i sina installationer. Prototypen kunde läsa av värdena med ungefär samma noggrannhet som ett kommersiellt instrument som använder sig av samma mätteknik som prototypen. Uppdateringsfrekvensen var dock lägre än hos ett kommersiellt instrument. Kommunikationen med PLC:n fungerade utan problem. Då ingen undervisning hölls i arbetets slutskede kunde inte lastfördelningen testas på en fullskalig anläggning. Lastfördelningsprogrammet klarade dock av att hålla rätt frekvens på en ensam generator och fungerade som tänkt när programmet testades i en simulator. Prototypen gav fel mätvärden vid kapacitiv last. Vid jämförelse med en kommersiell tångamperemeter visade sig mätfelet bero på mätmetoden då båda gav liknande resultat. Som referens användes en professionell elkvalitetsanalysator. Alla uppdragsgivarens krav blev uppfyllda och arbetet kommer att kunna användas i undervisningen. / This thesis was ordered by Kalmar Maritime Academy. The request was for a device that could measure active, reactive and apparent power, as well as frequency, voltage, current and cosϕ on a generator. The measured values would be communicated to a PLC for use in a load sharing program between a number of generators in the course Tillämpad elteknik, 15 ECTS. In that course the students constructs a three-generator electric power grid. Included in the request was also to program a load sharing program. The prototype being constructed was based on the Arduino Ethernet, and the communication was enabled by means of the Modbus TCP/IP protocol over Ethernet. A load sharing program was created in the form of a function block which the student could import into the CoDeSys for use in the generator systems. The prototype could measure values with close to the same accuracy as a commercial available instrument that were using the same technique for measuring. The refresh rate was however lower than the commercial available instrument. Communication with the PLC worked without any issues. No full-scale testing could be done since no course was held during the final stages of the thesis, however the load sharing program could keep frequency on a single generator alone and worked in a simulated soft environment. Measuring errors occurred when measuring a capacitive load. When comparing to a commercial available clamp meter, the same errors occurred. As a reference a professional power and energy quality analyser was used. All the requests were fulfilled and the result of this thesis will be used in the educational programme at the Academy.