Abstracts of Factory Automation 2013 21-22 May, 2013 Veszprém
FactoryAutomation 2013 PROGRAM Veszprém, Egyetem u. 10. Building B 21st MAY 2013 8:00 Registration (ground floor) 10:00 10:30 Opening Ceremony Ferenc Friedler (University of Pannonia), Martin A. Dale (Siemens), Gyula Porga (Municipality of Veszprém Town of County Rank), László Monostori (Chair) 10:40 12:50 Plenary Lectures Sándor Elek, department manager of Industrial Solutions Evopro: Autóipari projektek kihívásai és egy előre mutató műszaki megoldás bemutatása Miklós Boros, senior manager DENSO Manufacturing Hungary Ltd.: Denso, Development & Collaboration 12:30 Lunch 13:30 15:30 Sessions 15:30 16:00 Coffee break 16:00 17:30 Sessions 8:30 10:30 Sessions 10:30 11:00 Coffee break 11:00 13:00 Sessions 13:00 Lunch 22nd MAY 2013 14:45 Factory visit Continental Automotive (Veszprém) 2
Exhibitors and sponsors of the event: Biomarker CAD- Design Evopro graphit IEEE Infocontrol Hungaria Magyar Elektronika MATE National Instruments Pannon Egyetem Siemens S6 Mérnök Iroda Trodimp-R 3
CONTENT INDUSTRIAL COMMUNICATION AND SENSOR NETWORKS Önszerveződő, vezeték nélküli szenzorhálózaton alapuló hőmérséklet- és páratartalom mérő rendszer fejlesztése... 7 A Survey on Demand Side Management Solutions in Smart Grids... 7 Typifying Purchase Life-cycles of Electronic Spare Parts Using Fuzzy Similarity Metrics... 8 PLANNING AND OPTIMIZATION Path Planning for Remote LaserWelding Operations Using Collision Maps... 10 Practical application of the P-graph methodology: Regional Optimizer (RegiOpt)... 11 Optimized Network DeploymentforIndustrialControl Systems... 12 Folyamat-szimuláció megbízhatóságának alátámasztása ipari környezetben... 12 PRODUCT AND PROCESS DESIGN Acoustical System Identifier Implementation on NI crio... 14 Ionos folyadékok alkalmazása korszerű energiatároló cellákban... 15 Turning of Composites... 16 Design of a new chemical injection pump system... 16 SIMULATION AND OPTIMIZATION OF PRODUCTION SYSTEMS Investigation of manufacturing systems using timed colored Petri nets... 18 Recent issues in simulation supported control of large-scale production systems. 19 Simulation and Optimization of Production Systems... 19 PLANNING AND MONITORING Novel approach for flexible milkrun logistics planning... 21 A model based diagnosis method for discrete dynamic processes using event sequences... 22 Intelligent parking system solution... 23 MODEL BASED PROCESS AND PRODUCT DEVELOPMENT Correction of Highlight Line Structures... 25 Enhancing robotic screwdriving with a softness function... 25 SCADA based user interface for discrete event simulation analysis... 26 4
AUTOMATION TOOLS AND SOLUTIONS Demand & Distribution Manager (DDM) application in the oil industry... 28 Decentralizált IO megoldások az ipari automatizálásban... 29 Biztonsági automatizálás... 30 TOOLS OF PROCESS AUTOMATION AND DEVELOPMENT SMART-FRAME to generate SMART SMEs... 32 Egy fejlesztői platform minden automatizálási feladatra... 34 3D Inspection Technology for Industry... 34 AUTOMATION AND QUALITY CONTROL Methods of obtaining production data and their representation... 36 Kamerás ellenőrzőrendszerek a minőségellenőrzés szolgálatában... 36 Title Validation and Performance Monitoring of Online Analyzers... 37 AUTOMATION AND QUALITY CONTROL Holonic system of quality control InMoSys QC... 39 Influence of Aluminum Can flatness on heat dissipation of elcaps... 39 Analog cluster test using mixed signal boundary scan test method... 40 SCHEDULING AND MONITORING OF MANUFACTURING PROCESSES Hybrid Dynamical Approach Provides High Quality Scheduling for Flexible Manufacturing Systems... 42 Immediate event-aware model and algorithm of a general scheduler... 43 Algorithm development for the Megameter-III telemetry system to estimate the parameters of an extremely low fuel consumption internal combustion engine.. 44 OTDK-DÍJAZOTT HALLGATÓK 5
INDUSTRIAL COMMUNICATION AND SENSOR NETWORKS BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 1 CHAIR: GYULA SIMON (UNIVERSITY OF PANNONIA) 13:30 Trohák Attila (University of Miskolc) Önszerveződő, vezeték nélküli szenzorhálózaton alapuló hőmérsékletés páratartalom mérő rendszer fejlesztése 14:00 Rajmund Drenyovszki (Kecskemét College) A Survey on Demand Side Management Techniques in Smart Grids 14:30 Tamás Jónás (Flextronics) Typifying Purchase Life-cycles of Electronic Spare Parts Using Fuzzy Similarity Metrics 6
ÖNSZERVEZŐDŐ, VEZETÉK NÉLKÜLI SZENZORHÁLÓZATON ALAPULÓ HŐMÉRSÉKLET- ÉS PÁRATARTALOM MÉRŐ RENDSZER FEJLESZTÉSE Trohák Attila, Biró Zoltán, Méhes László Miskolci Egyetem Az ipari üzemek gyártócsarnokaiban a gyártósorok, gépek üzemelése során gyakran jelentős hőtermelés történik. A légtechnikai rendszerek behangolása során fontos, hogy egy időben, több helyen legyen lehetőség a hőmérséklet és páratartalom mérések elvégzésére, ezen adatok gyűjtésére. Jelen cikk célja egy általunk kidolgozott megoldás egyes részleteinek bemutatása, mely vezeték nélküli, önszerveződő szenzorhálózati egységekből épül fel. A SURVEY ON DEMAND SIDE MANAGEMENT SOLUTIONS IN SMART GRIDS Rajmund Drenyovszki Kecskemét College New generation electricity network called Smart Grid is a vision for a cleaner, more efficient and cheaper electricity generation, transmission and distribution system. One of the major challenges of Smart Grid is to incorporate renewable energy resources: the uncertainty of these sources cannot be compensated by the control of fossil generators because of their large time constants. One solution to this problem is influencing the demand side by controlling the consumption and incorporating energy containers like batteries of electric or hybrid vehicles. Balance between supply and consumption is crucial since oversupply means waste of energy, while undersupply causes performance degradation of the grid parameters (e.g. phase, voltage level, etc.). In this paper new Demand Side Management techniques will be surveyed, which are algorithmic solutions for the new challenges and are successful candidates to increase efficiency of the Smart Grid. The new strategies can be gr ouped as scheduling of charging electric vehicles, real time pricing and direct control of smart appliances. 7
TYPIFYING PURCHASE LIFE-CYCLES OF ELECTRONIC SPARE PARTS USING FUZZY SIMILARITY METRICS Tamás Jónás Flextronics This paper introduces a method that can be applied to typify the life-cycle curves of end of life (EOL) spare parts that belong to the same commodity category. The approach presented here is based ona fuzzy similarity metric that we utilize to measure the similarity between any two standardized demandtrends. Having the standard demand trends of EOL spare parts typified, and assuming that the demandtrend of a spare part, which is active from purchasing point of view, has a life-cycle similar to one of thetypified standard demand trends, this latter one can be used to forecast the purchase demand of the activecomponent. The introduced method is mainly advantageous in long term forecasting, it can be especiallyuseful in supporting purchase planning decisions in the ramp-up and declining phases of purchase lifecycles,and its efficiency is backed up by empirical results from real life applications. 8
PLANNING AND OPTIMIZATION BUILDING B, SECOND FLOOR, CONFERENCE CENTER LECTURE ROOM CHAIR: TIBOR CHOVÁN (UNIVERSITY OF PANNONIA) 13:30 Viktor Buzga / András Kovács (MTA SZTAKI) Path Planning for Remote Laser Welding Operations Using Collision Maps 14:00 Márton Frits (University of Pannonia) Practical application of the P-graph methodology: Regional Optimizer (RegiOpt) 14:30 Péter Bóna (Com-Forth) Optimized Network Deployment for Industrial Control Systems 15:00 Perger József (Audi) Folyamat-szimuláció megbízhatóságának alátámasztása ipari környezetben 9
PATH PLANNING FOR REMOTE LASERWELDING OPERATIONS USING COLLISION MAPS Viktor Buzga 1, András Kovács 2 1 Department of Measurement and Information Systems, Budapest University of Technology and Economics 2 Fraunhofer Project Center for Production Management and Informatics, Computer and Automation Research Institute, Hungarian Academy of Sciences Remote Laser Welding (RLW) is a recent and highly productive joining technology, whose application is spreading quickly in the automotive industry. However, computerized support for robot programming hardly exists for this new technology. This paper proposes a novel approach to one of the core problems in off-line robot programming, the integrated robot path planning and welding stitch sequencing problem for RLW. The objective is minimizing the welding cycle time. The problem is modeled as a generalized traveling salesman problem over a pre-generated map of collision-free positions in the 3D space, and it is solved by local search. Computational experiments prove that the proposed approach achieves a massive reduction of cycle time compared to an earlier approach in the literature, while collision detection ensures the feasibility of the calculated robot path. 10
PRACTICAL APPLICATION OF THE P-GRAPH METHODOLOGY: REGIONAL OPTIMIZER (REGIOPT) Márton Frits 1, Nora Niemtez 2, Istvan Heckl 1, Adrián Szlama 1, Michael Narodoslawsky 2 1 University of Pannonia, Department of Computer Science and Systems Technology 2 Institute for Process and Particle Engineering, Graz University of Technology A novel application of the P-graph methodology is proposed here for designing optimal energy conversion infrastructure for a small region. This task is a complex combinatorial problem, which needs substantial economic and engineering insight; moreover, sustainability issues becomes more and more relevant. Decision makers need an easy to use tool, which helps them to select among alternative scenarios. The Regional Optimizer (RegiOpt) is introduced here to achieve this goal. RegiOpt is based on the P-graph framework, which was developed at the University of Pannonia, and on the sustainable process index (SPI), which was introduced at Graz University of Technology. From the collaboration of these two parties, a powerful tool, for designing cost-effective and environmentally sustainable supply chains, was constructed. RegiOpt applies the P-graph methodology.p-graph methodology already proved its usefulness on many areas ranging from synthesis in chemical engineering until vehicle routing problem. There are freely available programs for creating and solving process network synthesis (PNS) problems called PNS-Studio and PNS- Draw. Nonetheless, modelling a problem requires large amount of information about energy conversion processes, prices, conversion rates, yields, and so on. Thedevelopers of the sustainable process index (SPI) have internationally recognized expertise in this field. The combined research of the two groups has created a web application where the optimal energy conversion infrastructure of a region can be designed. The user does not have to be concerned with problem modelling because it is already done in the form of a so called maximal structure.numerical values for prices, yields are also given in advance, but they can be simply modified if needed. Problems can be createdby filling out a questionnaire and the results are displayed instantly. A comparison is also given between the proposed solution and the business as usual solution. The comparison involves both the economic and the sustainability aspects. Acknowledgement: The authors acknowledge the help of project TÁMOP-4.2.2/B-10/1-2010-0025. 11
OPTIMIZED NETWORK DEPLOYMENTFORINDUSTRIALCONTROL SYSTEMS Péter Bóna Com-Forth Traditional fieldbus networks were, and some still are, isolated automation systems which require extensive local monitoring and routine onsite maintenance. To increase productivity and reduce operating costs, many manufacturers and plant operators have deployed industrial Ethernet to converge remotely isolated fieldbus systems for centralized control and monitoring. In addition to systems interoperability, integration of fieldbus segments and industrial Ethernet networks will require the optimization of PLC network performance and manageability. In my presentation I will show how PLC network optimization can ensure high network availability, simplify network monitoring and configuration, and maximize network lexibility. FOLYAMAT-SZIMULÁCIÓ MEGBÍZHATÓSÁGÁNAK ALÁTÁMASZTÁSA IPARI KÖRNYEZETBEN Perger József Audi Napjainkban kulcsfontosságú tényező az elkészített folyamat szimulációs modellek validálása, hiszen erre támaszkodva vizsgáljuk a változtatások kihatásait és egyben támogatható a termelés szempontjából jelentős döntések meghozatala. A kutatás során egy komplett gyártósor adatgyűjtő rendszeréből 1 hónapra visszamenőleg kinyert adatok szimulációs modellbe történő implementálásával vizsgáltuk a modell. 12
PRODUCT AND PROCESS DESIGN BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 2 CHAIR: MIKLÓS GERZSON (UNIVERSITY PANNONIA) 13:30 Zénó Dömötör (Kecskemét College) Acoustical System Identifier Implementation on NI crio 14:00 Göllei Attila (Pannon Egyetem) Ionos folyadékok alkalmazása korszerű energiatároló cellákban 14:30 János Líska (Kecskemét College) Turning of Composites 15:00 Viktor Füvesi (University of Miskolc) Design of a new chemical injection pump system 13
ACOUSTICAL SYSTEM IDENTIFIER IMPLEMENTATION ON NI CRIO Zénó Dömötör Kecskemét College Recently diagnostics of state of lifecycle in production systems came to the fore, resulting in decreasing the probability of outages. One possible approach is measurement of the transfer function of the underlying acoustical system. In this paper an implementation of a Maximum-Length-Sequence-based network analyser will be presented that fits to industrial environment. The identification of acoustical systems has several challenges, namely: (i) Acoustical sensors and actuators are very expensive that is why number of measurement channels has to be decreased to a minimum level, hence time domain solution are preferred (ii) The span of the underline discretised impulse responses are extremely long (often 10^5-10^6 ) requiring huge computational power. (iii) Applying Dirac-impulse excitation results in very pure SNR because of the small signal energy. To overcome these difficulties we implemented the Maximum-Length-Sequent based measurement method onto the NI crio which ensures all the necessary capabilities. 14
IONOS FOLYADÉKOK ALKALMAZÁSA KORSZERŰ ENERGIATÁROLÓ CELLÁKBAN Göllei Attila Pannon Egyetem Az ionos folyadékok kutatása és alkalmazása iránt világszerte növekedett az érdeklődés, különösen a petrolkémia, a nukleáris ipar, a gáz- és olajipar, a vegyipar és az elektrokémiai ipar érdeklődése jelentős. Az ionos folyadékok alkalmazása tekintetében, különösen a mikrohullámú térben ionos folyadékokkal megvalósított kémiai műveletek (szerves kémiai szintézisek, extraxciós,- katalitikus, stb. műveletek) terén nyílnak új távlatok, amint a vonatkozó kutatások ugrásszerűen növekvő száma, eredménye, a kutatási irányok bővülése egyértelműen bizonyít. Az ionos folyadékok viszonylag magas forráspontja miatt a műveletek szélesebb hőmérséklettartományban végezhetőek, és környezetbarát megoldást jelentenek az általában alacsony hőmérsékleten párolgó, mérgező hagyományos oldószerek kiváltása révén. Felhasználási területük egyre szélesebb körben terjed ki a korszerű akkumulátorcellák elektrolitjaként történő alkalmazásukra. Elektrolitoként történő alkalmazásuk fontos előfeltétele, az ionos folyadékok egyéb fizikai és kémiai tulajdonságainak ismerete. Kutatásaink elsősorban a dielektromos tulajdonságok vizsgálatára, a viszkozítás és a villamos vezetőképesség hőmérsékletfüggésének vizsgálatára terjednek ki. A mérési eredmények alapján kijelenthetjük, hogy mindhárom előbb említett tulajdonság jelentős hőmérsékletfüggést mutat az ionos folyadékok esetében. Ezek ismerete fontos az alkalmazások felhasználhatóságának, gyártásuk megtervezésének és optimalizálásának előkészítési folyamataiban. Különösen fontos abból a szempontból, hogy ezek az energiatároló cellák felhasználásul során széles hőmérsékletkülönbségeknek vannak kitéve. Az előadás bemutatja a mintaanyagok felhasználási lehetőségeit és a mérési eredményeket. 15
TURNING OF COMPOSITES Dr. János Líska, Balázs Gál Kecskemét College Composites are characterized byhigher strength and unique properties than metals. These materials become more, and more popular. Main application areas of composites we can mention as: automotive industry, reactor technique, chemical industry, entertainment industry and sports-related industries. Today, compositesare used not only with flat surfaces and free form surfaces, but materials with round surfaces, too. They have to be machined (turned) that assembled with metal parts can be built-in. During experiments we used a GFRP (Glass Fibre Reinforced Plastic) part with round surface. We used full factorial experiment and by the help of MINITAB software we varied four factors (vc; f; rε; κr). During the experiments we measured: the cutting temperature by infrared camera, cutting forces by the help of dynamometer and we measured surface roughness too. We evaluated the results statistically and graphically. Our goal is to help the development of composite-material industry and to define the required parameters at turning. DESIGN OF A NEW CHEMICAL INJECTION PUMP SYSTEM Csaba Vörös, Viktor Füvesi, Ákos Pintér University of Miskolc In this paper the main feature of chemical injection systems are detailed. Pneumatic and electric powered systems were investigated. Structures and main properties are discussed. Two examples are shown, a commercial system and a newly developed system. 16
SIMULATION AND OPTIMIZATION OF PRODUCTION SYSTEMS BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 1 CHAIR: JÁNOS ABONYI (UNIVERSITY OF PANNONIA) 16:00 Miklós Gerzson (University of Pannonia) Investigation of manufacturing systems using timed colored Petri nets 16:30 András Pfeiffer (MTA SZTAKI) Recent issues in simulation supported control of large-scale production systems 17:00 János Jósvai / Károly Kardos (Széchenyi István University) Simulation and Optimization of Production Systems 17
INVESTIGATION OF MANUFACTURING SYSTEMS USING TIMED COLORED PETRI NETS A. Leitold, B. Márczi, A. Pózna, M. Gerzson University of Pannonia Models are often used for the description and investigation of complex systems even if they cannot be the perfect image of the investigated system. The course of a manufacturing system can be split up to distinct steps of technological sub processes which can take place in serial or parallel way. Petri net based models are useful for the investigation of these steps especially in case of discrete event systems. During the design process of a manufacturing system, a model of the faultless operation of the system is most often created, but the integration of possible faults into it could give important information for more complex investigation of the system. In our previous work [1] we could integrate fault events with different occurring possibilities into low level Petri net models of manufacturing systems in such a way that the size of the model remained almost the same. In this work we apply the above fault integration method in the case when the faultless operation of the system was modeled by a high level, colored Petri net. The investigated manufacturing system consists of two manufacturing lines and a robot serving them. We assume that faults can occur in the manufacturing line. In low level Petri nets the transitions fire instantaneously, but the events of a real system take place for a certain amount of time influencing the operation of the system. Therefore, a timed colored Petri net model of the system was constructed in order to achieve more realistic investigations. The faultless and fault containing models were implemented in CPNTools [2] both for timed and non-timed cases. There are two possibilities for the investigation of a manufacturing system in CPNTools: the simulation and the analysis of the reachability graph. In case of fault modeling using different occurring possibilities, the standard reachability graph does not give information about the probability of the different occurring states of the system. Therefore, a special software module, called the OGAnalyzer has been developed for solving this problem. Weights can be assigned to the arcs of the reachability graph and the software calculates the probability of each node in the reachability graph, i.e. of each operational state of the system. OGAnalyser solves the search problems on the reachability graph efficiently even when the graph contains thousands of nodes. The user can perform different searches relating to places, tokens or colors referring to operational units, pieces, or faults. 18
RECENT ISSUES IN SIMULATION SUPPORTED CONTROL OF LARGE-SCALE PRODUCTION SYSTEMS András Pfeiffer 1, Botond Kádár 1, Gergely Popovics 1, László Monostori 1,2 1 Fraunhofer Project Center on Production Management and Informatics at Institute for Computer Science and Control, Hungarian Academy of Sciences 2 Faculty of Mechanical Engineering, Budapest University of Technology and Economics In production systems difficulties emerging from unexpected tasks and events, non-linearities, and a multitude of interactions, while attempting to control various activities in dynamic shop floors. The paper reviews the recent issues arising during simulation modeling of large-scale production systems: data gathering, data processing, model formulation and the interaction with the decision maker. Based on real industrial needs, a discrete-event simulation-based decision supporting system is proposed, supporting the analysis of diverse control settings and rules, by automatically mirroring the current state of large-scale production systems in digital models. The discrete-event digital model is built in an automated way (referred to as self-building simulation) and the data necessary for the model are taken from a manufacturing execution system (MES). The main findings and experiences gained are introduced through several case-studies, covering the various aspects of simulation modeling for decision support. SIMULATION AND OPTIMIZATION OF PRODUCTION SYSTEMS Dr. János Jósvai, Dr. Károly Kardos Széchenyi István University In this article several optimization methods of the permutation flow shop problem are investigated. An improved heuristic method of optimization willbe introduced. Based on the research analysis, a planning aid for selectionof appropriate optimization Tools is described, which takes the optimizationpotential and the calculation time into consideration. 19
PLANNING AND MONITORING BUILDING B, SECOND FLOOR, CONFERENCE CENTER LECTURE ROOM CHAIR: LÁSZLÓ MONOSTORI (UNIVERSITY OF PANNONIA) 16:00 Dávid Gyulai (MTA SZTAKI) A local-search-based solution for milkrun logistics optimization 16:30 Attila Tóth (University of Pannonia) A model based diagnosis method for discrete dynamic processes using event sequences 17:00 Csaba Major (Evopro) Intelligent parking system solution 20
NOVEL APPROACH FOR FLEXIBLE MILKRUN LOGISTICS PLANNING Dávid Gyulai 1,2, László Monostori 1,2 1 Fraunhofer Project Center for Production Management and Informatics, Computer and Automation Research Institute (SZTAKI) 2 Budapest University of Technology and Economics Department on Manufacturing Science and Technology In order to satisfy the material supply needs of the large scale shop-floors and production systems, different logistics solutions are applied. In lean manufacturing systems, the material supply is pulled by the demands of the assembly processes; therefore a milkrun service is applied to support the production without glitches. The milkrun logistics planning is a special case of the vehicle routing problem (VRP), and requires effective solution approach to satisfy the various constraints, and minimize the cost of the service. The paper gives an overview about the most efficient VRP solver algorithms, and proposes a novel initial solution generation heuristics which is specially focused on flexible milkrun planning. In order to demonstrate the capabilities of the solution, a software environment is introduced which concentrates on the main industrial requirements of logistics planning like quick response, effective layout definition and order handling. 21
A MODEL BASED DIAGNOSIS METHOD FOR DISCRETE DYNAMIC PROCESSES USING EVENT SEQUENCES Attila Tóth 1,2, Katalin M. Hangos 1,2, Ágnes Werner-Stark 1 1 University of Pannonia, Department of Electrical Engineering and Information Systems 2 Computer and Automation Research Institute, Process Control Research Group A novel model-based fault detection and diagnosis method is proposed in this paper that is based on following event sequences (traces) measured in a discrete dynamic process. The continuous range space of the measured variables is discretized using a qualitative value set. The model of the nominal and faulty operation modes are given in the form of event sequences, that are organized according to qualitative regions defined in the extended state space of the process. The extended state space is spanned by the measurable state variables and by the discrete value of the measurable input variables. The event sequences are defined using extended procedure HAZID tables. To each of the qualitative regions an extended procedure HAZID table is constructed by the user, these tables are connected to each other through boundary events. The diagnosis consists of the following steps. (1) Detecting deviations from the nominal event trace. (2) Exploring the root causes of the deviations by reasoning over the procedure HAZID tables. 22
INTELLIGENT PARKING SYSTEM SOLUTION Csaba Major, Péter Ábel, Bálint Péter Csenkey-Bencsik, Gyula Horváth Evopro Worldwide spread of motorization and urbanization raises new issues for city-dwellers. One of the key concerns of urban traffic is the growing size of the space occupied by parking cars. Development of industrial automation has now reached the level where reliable and efficient solutions can be given into the hands of parking garage designers. This evolution process makes it possible to develop a new generation of parking garages. Our article presents the technical solutions of a large-scale automated parking garage, especially the data acquisition, visualization and control system designed by our company. We highlight problems which (according to our experience) are the key points of designing comparable systems. 23
MODEL BASED PROCESS AND PRODUCT DEVELOPMENT BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 2 CHAIR: GYÖRGY KOVÁCS (MTA SZTAKI) 16:00 György Gyurecz (Óbuda University) Evaluation and Correction of Highlight Line Structures 16:30 György Tomozi (Széchenyi István University) Enhancing robotic screwdriving with a softness function 17:00 Csaba Kardos (MTA SZTAKI) SCADA based user interface for discrete event simulation analysis 24
CORRECTION OF HIGHLIGHT LINE STRUCTURES György Gyurecz 1, Gábor Renner 2 1 Óbuda University, Department of Machine Construction 2 MTA SZTAKI Evaluation of highlight lines is a well known method applied in the design and correction of high quality industrial surfaces (e.g. car bodies, home appliances). The method employs a set of linear light sources, reflected on the surface and tries to eliminate irregularities: unsmoothness, sharp change in curvature, uneven distribution on the surface. Adjustment of highlight line structures in present day engineering practice is performed by a cumbersome and time consuming handwork. We propose an automated method for correcting highlight line structures, suitable to adopt in a CAD environment. The correction is based on the distance and angle functions defined on the highlight line structure. They measure the irregularity of the highlight line pattern. Points of the new, corrected highlight lines are calculated by using this functions and applying a smoothing process. In the paper, improvement of highlight line structures of several industrial surfaces are demonstrated. ENHANCING ROBOTIC SCREWDRIVING WITH A SOFTNESS FUNCTION György Tomozi, Dr László Hodossy Széchenyi István University, Department of Automation The paper describes a Scara robot with a screwdriver system made by Atlas Copco. We prepared a Software programme for an arm softness function, thus enhancing the screwdriving process. This function models the human hand with a spring constant. Therefore we could use the screwdriver push to start function to start the tightening. We have tested our system in two different materials, and good results have been obtained in the course of loosening and tightening. 25
SCADA BASED USER INTERFACE FOR DISCRETE EVENT SIMULATION ANALYSIS Kardos Csaba MTA SZTAKI Application of Discrete Event Simulation (DES) plays an important role in the evaluation and analysis of manufacturing systems behavior. Numerous recent research works are dealing with broadening the usability and applicability of DES. One aspect of these activities focuses on improving model building capabilities in order to ensure model reusability (e.g. automated model building). Another field of enhancements is targeted towards simplifying the process of simulation analysis and evaluation in order to reduce the required modeling expertise and simulation specific knowledge. The development of more user-oriented and dynamical interfaces for simulation projects can significantly contribute to achieving this goal. The subject of the paper is an industrial use-case in which the simulation interface was provided by a mirrored instance of the applied Supervisory Control and Data Acquisition (SCADA) system of the factory and the simulation model was connected to this instance. This resulted in an environment where the user has to interact only with a program that is already familiar with, while the underlying DES model stays hidden and provides all the inputs and results to the mirrored SCADA system. Therefore there is no need for additional simulation specific knowledge to execute simulation scenarios (e.g. WHAT-IF analysis) and evaluate the results. Moreover, as the SCADA system displays an abstract representation of the system to be modeled, it was also used to define the level of abstraction and the details of adjustments of the simulation model. 26
AUTOMATION TOOLS AND SOLUTIONS BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 1 CHAIR: GYÖRGY BARADITS (SIL4S) 8:30 István Heckl (University of Pannonia) Demand & Distribution Manager (DDM) application int he oil industry 9:00 Zólomy Zsolt (Infocontrol) Új technológiák a biztonsági érzékelés és vezérlés területén 9:30 Zoltán Kása (Balluff) Decentralized IO solutions in the industrial automation 10:00 Baradits György / Madár János (SIL4S) TOO4S_M SW bemutatása 27
DEMAND & DISTRIBUTION MANAGER (DDM) APPLICATION IN THE OIL INDUSTRY Márton Frits 1, László Halász 1, Péter Borbás 2,Bálint Pintér 1, Adrián Szlama 1, István Heckl 1 1 Department of Computer Science and System Technology, University of Pannonia 2 Supply Chain Management, MOL Plc. A software tool is proposed here to support the daily operation of MOL Plc to register the individual sales demands of different products. MOL, the leading Hungarian oil company, has longstanding relation with the University of Pannonia both in education and joint research. One of the major results of these research activities is the ProdSim tool.it is used by the SCM department of the company to assist and validate the short term scheduling of the pipelines, the so called pipe program. ProdSim is an obvious success as it made possible to extend the pipe program from 5-7 days to a whole month and made possible to deal with extremely low or high inventory levels. DDM aims to extend further the integration between the various IT systems of the SCM department by creating a platform for the salesman in different countries to register the sales demands. Sales demand can be partitioned into two categories. The first group, mainly the Hungarian domestic sales, can be estimated fairly. These demands are not registered one by one, but statistical methods are used to get a good projection. The demands in the second group are registered and tracked through their life-cycle individually. Previously, an Excel based application was used for this registration, but it was not integrated into other IT systems like ORION, LOGIR, RFMS, and it had limited capabilities. The new DDM application overcomes these limitations. For example, it has a built-in confirmation protocol for the demands. It means, if a demand is recorded then the Logistics, Refinery, SCM department can signal if that particular demand can be satisfied, namelyproduced, loadedand transferred. With its operation, DDM enhances the efficiency of SCM and ensures a greater transparency of the logistics activities. Acknowledgement: The authors acknowledge the help of project TÁMOP-4.2.2/B-10/1-2010-0025. 28
DECENTRALIZÁLT IO MEGOLDÁSOK AZ IPARI AUTOMATIZÁLÁSBAN Kása Zoltán Balluff Elektronika Kft. Az automatizálási rendszerek elméleti tárgyalása során a hangsúly elsősorban a szabályozási kör fő összetevőire esik: érzékelők, beavatkozók, központi egység. Csak a technikai megvalósítás során merül fel az a probléma, amelyet az elméleti vizsgálat során egy egyszerű vonallal megoldunk: az alkotórészeket össze kell kötni egymással. Ez, egy komoly, több szenzort és beavatkozót tartalmazó rendszer esetében komoly kihívás elé állíthatja a rendszer tervezőjét. A hagyományos megoldás a szenzorok, beavatkozók és a vezérlő egység direkt összekötése. (hardwired IO). E rendszer egy továbbfejlesztett, finomított megoldása a passzív elosztókat használó vezetékezés (hardwired I/O withjunctionblocks). Az utóbbi évtizedekben azonban, köszönhetően a kommunikációs megoldások terén tapasztalható fejlődésnek, az ipari buszrendszerekre építő, decentralizált IO egységeket tartalmazó kábelezési hálózatok terjedése volt megfigyelhető. (networked I/O). A fejlődés azonban töretlen, az evolúció következő állomása az elosztott, intelligens elemeket tartalmazó hálózatok alkalmazása (distributedmodular I/O). Ezek a hálózatok többnyire a kommunikációs lehetőségek hierarchikusan egymásra épülő szintjeit használják az információk továbbítására. További lényeges pontja az ilyen alapú rendszereknek, hogy nem csak a vezérelt folyamatra közvetlenül jellemző adatokat képes továbbítani (processdata I/O jelek, nyomás-, hőmérséklet adatok, távolság adatok stb.), hanem kihasználva a digitális kommunikáció adta lehetőségeket, a paraméterezés, és a diagnosztika széles tárházát nyújtják a felhasználónak, megkönnyítve ezzel a rendszer installációját, illetve a hibakeresést. Az elosztott, rendszerek egy sarkalatos eleme az utóbbi évek legújabb ipari kommunikációs fejlesztése az IO-Link szabvány. Az IO-Link egyszerű, alacsony áron megvalósítható adatátviteli forma, amely pont-pont összeköttetést biztosít a kommunikáló felek között. A vezérelt folyamatra jellemző adatok mellett, a szabvány beépített módon támogatja a különböző beállítási paraméterek mellett a diagnosztikai adatok átvitelét is. A nagyfokú rugalmasságot biztosító rendszer segítségével megoldható, hogy az automatizálási rendszer, mechanikai kialakítást tekintve legbonyolultabb részei (érzékelők, beavatkozók, kábelezése) szinte teljesen függetleníthetők legyenek a központi vezérlés megvalósításától. Az ipari automatizálás területén számos olyan innovatív megoldás létezik, amely igyekszik kihasználni az elosztott, moduláris rendszerek nyújtotta lehetőségeket. A cikk röviden bemutatja a fent felsorolt kábelezési megoldásokat, példákat említ a decentralizált I/O egységeket tartalmazó megoldásokra, rávilágít az ilyen rendszerek előnyire, hátrányaira, részletesen bemutatja az IO- Link kommunikációra épülő, elosztott, moduláris rendszerek kialakításának lehetőségeit, a rendszer nyújtotta képességeket. Ezt követően pedig bemutat egy két olyan innovatív megoldást, amely drasztikusan képes csökkenteni egy automatizálási rendszer felépítését, karbantartását. 29
BIZTONSAGI AUTOMATIZALAS Dr. Baradits György SIL4S Szeretnénk bemutatni a TOO4S_M SW-t, melyet a gyártás tervezéskor a gépek biztonságának az elemzésére és a gépek biztonsági rendszerének a verifikálására lehet használni. A TOOL4S_M megfelel az MSZ EN ISO 13849-1_Gépek biztonsága. Vezérlőrendszerek biztonságával összefüggő szerkezeti részek és az MSZ EN ISO 12100_2010_Gépek biztonsága_ Assessment&Reduction szabványoknak. A TOOL4S_M SW fő felhasználói a gép tervezők. 30
TOOLS OF PROCESS AUTOMATION AND DEVELOPMENT BUILDING B, SECOND FLOOR, CONFERENCE CENTER LECTURE ROOM CHAIR: PÉTER ARATÓ (BME) 8:30 György Kovács (MTA SZTAKI) SMART-FRAME to generate smart SMEs 9:00 Sipos Norbert (University of Pannonia) Csomagolási folyamat hatékonyságának javítása a Flextronics Kft. sárvári telephelyén 9:30 Móczó Vilmos (Siemens) Egy fejlesztői platform minden automatizálási feladatra 10:00 Ádám Kisari (MTA SZTAKI) 3D Inspection Technology for Industry 31
SMART-FRAME TO GENERATE SMART SMES George Kovacs, Géza Haidegger, Imre Paniti Sándor Kopácsi, Ádám Kisari MTA SZTAKI The paper presents the Central Europe Regional Development Fund s SMART-FRAME project, its recent results and plans for the next period. The consortium of 5 CE countries, 7 partners join their forces, as SMART HUBS, to promote the innovation results for the SMEs, especially for Start-ups, and Spinoffs. The focus areas are limited to the most high-tech. field of technologies, like material sciences, surface technologies, sensor-techniques, production technologies, and their integration into the manufacturing of SMART PRODUCTS. 32
CSOMAGOLÁSI FOLYAMAT HATÉKONYSÁGÁNAK JAVÍTÁSA A FLEXTRONICS KFT. SÁRVÁRI TELEPHELYÉN Sipos Norbert, Dr. Tarczali Tünde, Dr. Süle Zoltán, Hegyháti Máté Pannon Egyetem, Műszaki Informatikai Kar, Rendszer- és Számítástudományi Tanszék Termelővállalatok működésének különböző területein olyan folyamatokkal találkozhatunk, melyek hatékonysága optimalizálással nagymértékben javítható. A folyamattervezés eszközeinek felhasználásával meghatározható a gyártást vagy annak valamely részfolyamatát leíró optimális folyamatstruktúra, azaz eldönthető, hogy milyen terméket, milyen technológiával, milyen gyártási lépésekkel gyártsunk. Ipari környezetben általános probléma az elkészült termékek csomagolási sorrendjének meghatározása. Egy-egy termék csomagolási ideje függhet a termék típusától, előzetesen rögzített kritériumoktól, továbbá ha egy csomagolási folyamat több lépésre bontható, akkor az egyes lépésekben eltöltött idő is meghatározó. Egy optimális csomagolási sorrend felállításával tehát csökkenteni lehet az átlagos csomagolási időt, így a termék előbb éri el polcra kész állapotát. Mindezek együttese pedig magával vonja a vevői elégedettség és a gyártás hatékonyságának növelését is. Az EnterFlex 2012 tehetségkutató program keretében a Flextronics Kft. Sárvári telephelyén a termékek csomagolásának gyakorlatát vizsgáltuk. A megismert folyamat alapján két eszköztár elemeit is felhasználhatjuk az optimális megoldás számításakor: egyrészt gráfelméleti megközelítést alkalmazva alternáló utak keresésével megkapható az optimális megoldás, valamint egész értékű feladatként is modellezhető a probléma. Előadásunkban bemutatjuk e két megközelítést és részletesen szólunk a kapott eredményekről, amely alapján jelentősen sikerült csökkentenünk a csomagolásra fordítandó időt. A publikáció az Európai Unió, Magyarország és az Európai Szociális Alap társfinanszírozása által biztosított forrásból a TÁMOP-4.2.2.C-11/1/KONV- 2012-0004 azonosítójú Nemzeti kutatóközpont fejlett infokommunikációs technológiák kidolgozására és piaci bevezetésére című projekt támogatásával jött létre. 33
EGY FEJLESZTŐI PLATFORM MINDEN AUTOMATIZÁLÁSI FELADATRA Móczó Vilmos Siemens A TIA Portal legújabb, V12-es verziója magasra teszi a mércét az automatizálási iparágban. Az új, egyedülálló fejlesztői keretszoftver, tökéletesen illeszkedik az innovatív automatizálási eszközökhöz, most még több funkcionalitást nyújtva a beintegrált hajtás technológiának köszönhetően. A TIA Portal V12 lehetővé teszi a folyamatos, intuitív, eredményes mérnöki munkát a Simatic Step7, Simatic WinCC, Sinamics Startdrive és a Simatic Step7 Safety segítségével. 3D INSPECTION TECHNOLOGY FOR INDUSTRY Ádám Kisari, Géza Haidegger, János Nacsa, George Ákos MTA SZTAKI The paper gives a short overview of a Eureka EUROSTARS project, which has dealt with the development of 3D vision technology for inspection testing. The work was performed by an international consortium, consisting of Spanish, Austrian and Hungarian partners, both from research-oriented industrial SMEs, and from academic research institutes. 34
AUTOMATION AND QUALITY CONTROL BUILDING B, GROUND FLOOR, CONFERENCE ROOM CHAIR: JÁNOS ABONYI (UNIVERSITY OF PANNONIA) 8:30 Peter Hrubaník (Zilinská Univerzita) Methods of obtaining production data and their representation 9:00 Varga Dávid (National Instruments) Kamerás ellenőrzőrendszerek a minőségellenőrzés szolgálatában 9:30 Tibor Kulcsár (University of Pannonia) Validation and Performance Monitoring of Online Analyzers 10:00 Sleisz Gábor (Trodimp) Integrált termékjelölési megoldások az iparban 35
METHODS OF OBTAINING PRODUCTION DATA AND THEIR REPRESENTATION Peter Hrubaník Zilinská Univerzita The article deals with the methods of data collection from process level and the possibilities for further processing in the intelligent modular system of quality control InMoSys QC. Moreover, the article describes the advantages of the methods of data acquisition and integration role in the measuring system. KAMERÁS ELLENŐRZŐRENDSZEREK A MINŐSÉGELLENŐRZÉS SZOLGÁLATÁBAN Varga Dávid National Instruments Minden mérőrendszer sikerének kulcsa a megbízhatóság és a mérések ismételhetősége. Ezt főleg a gépi látásra épülő alkalmazások területén nehéz elérni. Előadásunk során bemutatjuk azokat a hardver-és szofver eszközöket, melyeknek a segítségével robosztus, akár valós idejű optikai méréseket végezhetünk. Esettanulmányokon keresztül ismertetjük,miként segíti a LabVIEW Grafikus Rendszertervezés a mérnököket optikai alkalmazásaik fejlesztésénél legyen szó minőségellenőrzésről, folyamatirányításról, automatizált tesztek futtatásáról vagy orvosi képalkotó feladatról. 36
TITLE VALIDATION AND PERFORMANCE MONITORING OF ONLINE ANALYZERS Tibor Kulcsár, Barbara Farsang, János Abonyi University of Pannonia Process variables characterising and influencing product quality has significant role in process control and optimisation. Advanced and classical control systems can be improved by online analysers and soft sensors to provide accurate and timely information for corrective actions or feedback control. We give a detailed overview of these solutions. Data and first- principle model based methodologies of soft sensor development are also presented. We show that not only soft sensors but all the models of APC (advanced process control) solutions require maintenance. Therefore, we discuss the main issues of APC, soft sensor, and on-line analyser maintenance. 0 Based on an application example taken from the literature we demonstrate that quality assurance techniques can be effectively used to automatise the related fault detection and decision support tasks. The performance of the NIR analyser of the diesel d uel mixing process of MOL is also presented to illustrate the applicability of this approach. The theoretical background of Statistical Quality Control used by these tools and per- formance and validation methods are also overviewed to provide information for the design and operation statistical quality control tools to monitor and control ongoing stability and precision and bias performance of selected analytical measurement systems. All of the presented techniques were implemented in MATLAB. The applicably of the developed tools is illustrated based on data collected at the diesel fuel mixing process. Since this analyser was not working properly during the time of analysis and no enough laboratory samples were collected, a dataset taken from MOL aromatic block gas chromatograph 3/102 head IP benzene content (m/m %) was analysed. 37
AUTOMATION AND QUALITY CONTROL BUILDING B, SECOND FLOOR, CONFERENCE CENTER SESSION ROOM 1 CHAIR: LÓRÁNT KOVÁCS (KECSKEMÉT COLLEGE) 11:00 Jan Rofar (Zilinská Univerzita) INMOSYS QC Holonic Quality Control System 11:30 László Kovács (Epcos) Influence of Aluminum can flatness on heat dissipation of Aluminum electrolytic capacitor 12:00 Zsolt Molnár (Óbuda University) Analog cluster test using mixed signal boundary scan test method 38
HOLONIC SYSTEM OF QUALITY CONTROL INMOSYS QC Ing. Jan Rofar, PhD. Zilinská Univerzita This paper depicts about holonic concept of intelligent modular system of quality control for specified spectrum of electro-technical and mechanical parts named InMoSys QC. To design of this holonic concept were used some basic recommendations and definitions from international standard IEC 61499. INFLUENCE OF ALUMINUM CAN FLATNESS ON HEAT DISSIPATION OF ELCAPS László Kovács 1, László Gál, Dénes Fodor 2 1 Epcos Kft, SZ ALU PD Department 2 University of Pannonia, Faculty of Engineering, Institute of Mechanical Engineering, Automotive Mechatronics Department The lifetime of aluminum electrolytic capacitors highly depends on their core temperature. The heat dissipation in general applications happens by the extended cathode which is in contact with the inner side of the can. In case of heat sink applications the most important heat transfer phenomenon is the heat conduction thought the bottom of the Aluminum can. The quantity of the dissipated heat is in direct proportion to the size of the heat transferred-surface which may cause increase of the capacitor lifetime. Therefore, the flatness value of the can bottom is critical. This paper presents a measurement method which can replace the expensive 3D measurement equipments and methods. Also shows an implemented measurement environment where data acquisition and visualization are automation by a LabVIEW based software. In addition, the article presents the influence of production methods on the flatness value of the capacitor and contains the flatness values of capacitors produced by leading manufacturers. 39
ANALOG CLUSTER TEST USING MIXED SIGNAL BOUNDARY SCAN TEST METHOD Zsolt Molnár Óbuda University, Kandó Kálmán Faculty of Electrical Engineering This article is about how to use mixed signal boundary scan (standardized as IEEE 1149.4) to measure analog circuits. The analog circuits can be considered as analog clusters, because they have not the infrastructure to connect to the analog and digital Boundary Scan lines. These analog circuits can be connected to integrated circuits containing the additional circuits of Boundary Scan, and can be tested as quadripoles. We take a proposal for some measurement methods characterizing these quadripoles. To involve these circuits into the testing by Boundary Scan may reduce the costs of testing mainly in field tests. If the test is performed during normal operation (or in a short interrupts of the normal operation) the occurring errors can be captured in early times. 40
SCHEDULING AND MONITORING OF MANUFACTURING PROCESSES BUILDING B, SECOND FLOOR, CONFERENCE CENTER LECTURE ROOM CHAIR: GÉZA HAIDEGGER (MTA SZTAKI) 11:00 János Somló (Óbuda University) Hybrid Dynamical Approach Provides High Quality Scheduling for Flexible Manufacturing Systems 11:30 Tibor Dulai (University of Pannonia) Immediate event-aware model and algorithm of a general scheduler 12:00 István Pintér (Kecskemét College) Algorithm development for the Megameter-III telemetry system to estimate the parameters of an extremely low fuel consumption internal combustion engine 12:30 Viktor Kovács (BME) Designing operator activities at automated assembly machines 41
HYBRID DYNAMICAL APPROACH PROVIDES HIGH QUALITY SCHEDULING FOR FLEXIBLE MANUFACTURING SYSTEMS János Somló, Imre Rudas Óbuda University, Budapest, Hungary The use of hybrid dynamical systems theory opens a new horizon for flexible manufacturing systems scheduling.. In the present paper the most important new result are described and the application isssues are discussed. The paper concentrates on the development of a feedback control law (switching law) resulting stable (implementable with finite buffers) and regular ( converging to periodic) processes 42
IMMEDIATE EVENT-AWARE MODEL AND ALGORITHM OF A GENERAL SCHEDULER Tibor Dulai, Ágnes Werner-Stark, Katalin Hangos University of Pannonia, Faculty of Information Technology, Department of Electrical Engineering and Information Systems A stochastic scheduling problem is considered in this work that considers work-pieces to be manufactured according to individual recipes that contain manufacturing steps performed by work-stations as resources. Unexpected stochastic breakdown of a workstation or the faulty termination of a recipe, when a manufacturing failure makes the work-piece out of specification, form the set of immediate events. A model and an algorithm are proposed as the basis of a scheduler, which take into account the possible immediate events, estimates their probability and suggests resource allocations which provide the best overall workflow even when an immediate event happens. This model includes the possibility of cooperation of the resources, that can give aid in case of an immediate event, like sudden technical failure of a resource. Immediate events are not exactly predictable, however, based on the previous experiences their probabilities can be estimated. Our model needs the properties of the resources (including how they can substitute other types of resources), the required sequence of them during the work-flow (i.e. the recipes), and the experiences about their behavior from the past. The proposed scheduling algorithm constructs a solution workflow, that reacts in the best way (in average) even for an unexpected event. The proposed model and scheduling algorithm will be illustrated on an industrial case study. Acknowledgements: We acknowledge the financial support of the Hungarian State and the European Union under the TAMOP-4.2.2.A-11/1/KONV-2012-0072. The publication has been supported by the European Union and the Hungarian Republic through the project TÁMOP-4.2.2.C-11/1/KONV-2012-0004 National Research Center for Development and Market Introduction of Advanced Information and Communication Technologies. 43