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Model-Based Virtual Commissioning of a Manufacturing Cell Control System
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2013 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

One of the preferred options of manufacturing organizations to survive in today’s market is to automate, increase flexibility and configurability of manufacturing lines. Control systems and Programmable Logic Controller (PLC) programming are quintessentially important part of an automation system. However, PLC programming and debugging takes time and is error prone; consequently, there has being a growing need for quick development of PLC programs and inexpensive code verification and validation methods. To meet the needs, this thesis paper presents a method of virtual development of control system for a fully automated manufacturing cell. The cell has two robots and five other machines, which each machine operating modes are modeled in MATLAB environment and PLC code is generated from the developed models. The model and their associated PLC code are verified and validated in virtual environments. Step-by-step development, verification and validation approaches are presented and argued. Results show that few hours of modeling efforts can generate thousands of lines of code; hence this method is expected to significantly reduce time, development efforts and costs associated with verification and validation of PLC code.

Keywords: PLC Code Generation, Simulink/Stateflow Model, Verification and Validation, Manufacturing Cell.

Abstract [sv]

Ett alternativ som föredras för tillverkning organisationer att överleva i dagens marknad är att automatisera, öka flexibiliteten och konFigurering av tillverkningslinjer. Kontrollsystem och Programmable Logic Controller (PLC) programmering är en grundlägande viktig del av ett automatiseringssystem. Dock tar PLC-programmering och debugging tid och är felbenäget, och därför har det funnits ett växande behov av snabb utveckling av PLC-program, billiga kodverifiering och valideringsmetoder. För att möta behoven, presenterar denna avhandling papper en metod för virtuell utveckling av styrsystem för en helt automatiserad tillverkning cell. Cellen har två robotar och fem andra maskiner, som varje maskin driftlägen modelleras i MATLAB miljö och PLC-kod genereras från de utvecklade modellerna. Modellen och tillhörande PLC-kod verifieras och valideras i virtuella miljöer. Steg-för-steg utveckling, verifiering och validering metoder presenteras och argumenteras. Resultaten visar att några timmars modelleringsinsatser kan generera tusentals rader kod, och därmed förväntas av denna metod att minska tiden, utvecklingsinsatser och kostnader förknippade med verifiering och validering av PLC-kod.

Nyckelord: PLC Code Generation, Simulink/ Stateflow Modell, Verifiering och validering, tillverkning Cell

Place, publisher, year, edition, pages
2013. , 89 p.
, Degree Project in Production Engineering Management, Second Level, 567
National Category
Engineering and Technology
URN: urn:nbn:se:kth:diva-129545OAI: diva2:652922
Available from: 2013-10-02 Created: 2013-10-02 Last updated: 2013-11-07Bibliographically approved

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