Generalized front-end controller design

M.E. Gerules, T.N. Faddis, B.G. Barr
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Abstract

Many manufacturing systems can be modeled as a hierarchical, distributed control structure in which each level of the hierarchy represents a different level of information abstraction. Tasks passed to each level from the previous levels are decomposed into a set of simpler tasks. If these simpler tasks are within the conceptual domain of the current level of the hierarchy, they are acted upon. If not, they are decomposed further to be passed onto the next lower level of the hierarchy. The decomposition of tasks frees the upper levels of the hierarchy to make global decisions about the manufacturing process. With the advent of the personal computer, microprocessor-based hierarchical distribution has become a reality upon the factory floor.

Today personal computers, PCs, account for the vast majority of cell controller installations. Among the reasons for this dominance are low cost, ease of programming, and the ability to combine the capabilities of third party products. Adding these capabilities to the manufacturing system increases flexibility creating an intelligent, closed loop environment. Within this environment, the PC takes on many roles. One of these roles is as a front-end controller. The front-end controller provides two basic functions for the manufacturing environment. First, the front-end controller provides a “plug” for systems integration. Equipment and software manufacturers have not yet agreed upon standards for system interfaces. That is, they cannot be plugged together as home stereo components can be; they are not “plug” compatible. The front-end controller provides this plug by creating an interface that allows previously incompatible systems to work together. Secondly, the front-end controller provides a local processing node within a level of the distributed manufacturing environment. The manufacturing environment needs this because much of today's equipment and software are underdeveloped. They lack the processing power to formulate the kinds of environment-based decisions necessary to achieve the implementation of the unmanned machine cell. The front-end controller bridges this gap enhancing the existing capabilities of equipment and software while adding new capabilities. Some of the new capabilities may be low level error recovery, a local database for equipment or tool histories, a local user interface, and data acquisition, assimilation, and management.

In a program sponsored by the National Institute of Standards and Testing Automated Manufacturing Research Facility (NIST AMRF), the University of Kansas (KU) has been developing work station level rules for a vertical machining work station. The vertical machining work station at KU consists of an American Robot, a Hurco KMC-3P Three Axis Vertical Milling Machine, an automated fixture, and a Sun Microsystems 4/260 work station controller. The architecture of the work station is based on the five level control system under implementation at the AMRF. Currently, the two lowest levels of the hierarchy, work station and equipment, are implemented at the University of Kansas Computer Integrated Manufacturing Lab.

During system integration of the equipment, it was necessary to design and implement several front-end controllers. Following the hierarchical abstraction of the rest of the manufacturing control hierarchy, a general model for the front-end controller was developed consisting of a common frame of reference, structure, and command set for the work station. The architecture of the front-end controller is modular and expandable allowing it to act as an open system in a complex environment. This technique allows the front-end controller to be ported from one piece of equipment to the next with little modification for the equipment's full integration within the work station, thus providing low integration and development time.

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通用前端控制器设计
许多制造系统可以建模为分层的分布式控制结构,其中层次结构的每个级别代表不同级别的信息抽象。从前一层传递到每一层的任务被分解成一组更简单的任务。如果这些更简单的任务在当前层次结构级别的概念领域内,则对它们进行操作。如果没有,则将它们进一步分解,以传递到层次结构的下一个较低级别。任务的分解使层次结构的上层能够对制造过程做出全局决策。随着个人计算机的出现,以微处理器为基础的分层分布已成为工厂车间的现实。今天,个人电脑(pc)占据了电池控制器安装的绝大多数。这种主导地位的原因包括低成本、易于编程以及能够结合第三方产品的功能。将这些功能添加到制造系统中可以增加灵活性,从而创建智能的闭环环境。在这种环境中,PC承担了许多角色。其中一个角色是前端控制器。前端控制器为制造环境提供两个基本功能。首先,前端控制器为系统集成提供了一个“插头”。设备和软件制造商尚未就系统接口的标准达成一致。也就是说,它们不能像家庭音响组件那样插在一起;它们不是“插拔”兼容的。前端控制器通过创建一个允许以前不兼容的系统一起工作的接口来提供这个插头。其次,前端控制器在分布式制造环境的某个级别内提供本地处理节点。制造业环境需要这一点,因为今天的许多设备和软件都不发达。他们缺乏制定各种基于环境的决策所需的处理能力,以实现无人机器单元的实施。前端控制器弥补了这一差距,增强了设备和软件的现有功能,同时增加了新功能。一些新功能可能是低级错误恢复、设备或工具历史的本地数据库、本地用户界面以及数据获取、同化和管理。在美国国家标准与测试自动化制造研究机构(NIST AMRF)赞助的一项计划中,堪萨斯大学(KU)一直在为立式加工工作站制定工作站级别规则。KU的立式加工工作站由一台美国机器人、一台Hurco KMC-3P三轴立式铣床、一个自动化夹具和一个Sun Microsystems 4/260工作站控制器组成。工作站的架构基于AMRF正在实施的五级控制系统。目前,最低的两个层次,工作站和设备,是在堪萨斯大学计算机集成制造实验室实现的。在设备的系统集成过程中,需要设计和实现多个前端控制器。在对制造控制层次结构的其余部分进行分层抽象之后,开发了前端控制器的通用模型,该模型由工作站的公共参考框架、结构和命令集组成。前端控制器的架构是模块化和可扩展的,允许它在复杂的环境中作为一个开放的系统。这种技术允许前端控制器从一个设备移植到下一个设备,几乎没有修改,设备完全集成在工作站内,从而提供低集成和开发时间。
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