Data Communication & Networking in Manufacturing System

1. Data Communication & Networking in Manufacturing System Nanang Ali Sutisna Master Eng. in Computer Integrated Manufacture Senior PLM Consultant, IBM Indonesia (retired) Senior Manager, Product Development Multistrada Arah Sarana

2. Data Communication & Networking in Manufacturing System Chapter 6Computers and Control Systems within Manufacturing

3. The Range and Scope of Computers withinManufacturing 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.

4. 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.

6. Programmable 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

7. The 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.

8. 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.

9. 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.

10. Interlocking CNC Machines to Robot

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

12. Data 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: Minimize errors occurring during transmission Provide a mechanism for detecting errors Check all incoming data Detect and/or correct any corrupt information through re-transmission procedures.

13. Ways 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.

14. Manufacturing Systems

15. Dedicated 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.

16. Hard 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.

17. Flexible 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

18. FMS 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.

19. Data Communication & Networking in Manufacturing System Key Technology of Digital Manufacturing

20. Key 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.

21. Various 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.

22. Various Digital Technologies in Product Lifecycle Digital Equipment and Digital Processing Technology 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. • Digitized modeling of equipment • Digital equipment’s networking

23. Various Digital Technologies in Product Lifecycle Digital Processing Technology Fig. 8.3 The composition of digital processing

24. Various Digital Technologies in Product Lifecycle The Technology of Digital Maintenance and Diagnosis Fig. 8.5 The key technology of product digital maintenance

25. Various Digital Technologies in Product Lifecycle The Technology of Digital Maintenance and Diagnosis Fig. 8.7 The Function of Remote Failure diagnosis system

26. Various Digital Technologies in Product Lifecycle • The key technologies of digital logistics: • Logistic informatization: Related technology includes bar code technology, network communication technology, database technology, electronic commerce technology, enterpriseresource 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

27. Various Digital Technologies in Product Lifecycle Key Technology of Digital Logistics Fig. 8.8 The structure of digital logistic system

28. Various Digital Technologies in Product Lifecycle 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

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

30. Resource and Environment Technology inDigital Manufacture Resource Organization and Management Technology The manufacturing resource information sharing based on network

31. Resource and Environment Technology inDigital Manufacture The Integration of Digital Manufacturing Resource The product information integration base on XML

32. Resource and Environment Technology inDigital Manufacture The Integration of Digital Manufacturing Resource PDM system and its integration • 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.

33. Resource and Environment Technology inDigital Manufacture Manufacturing Grid: the Management and Scheduling of Resources 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

34. Resource and Environment Technology inDigital Manufacture The Architecture of Manufacturing Grid

35. Resource and Environment Technology inDigital Manufacture The Prototype System of Manufacturing Grid

36. Management Technology in the Digital ManufacturingProcess 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

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

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

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

40. Control Technology in Digital Manufacture 2. Virtual NC Technology

41. Control Technology in Digital Manufacture 3. The Embedded Control Technology

42. Digital Recognition and Integration Technology in 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

43. Digital Recognition and Integration Technology in Product

44. Digital Recognition and Integration Technology in Product