ProOpter: An advanced platform for production analysis and optimization

This paper presents the prototype of an advanced platform for production analysis and optimization, referred to as ProOpter. The platform was developed to support the recently derived concept of holistic production control (HPC), which relies on model-based control. The prototype is comprised of a set of off-line and on-line modules. The off-line modules support the definition of key performance indicators (KPIs), the selection of the most influential input (manipulative) variables, and the identification of a simple production model from historical data. The on-line modules enable KPI prediction and suggest actions to the production manager, employing model-based production control and/or optimization techniques. In this way, a new decision-support reasoning based on historical production data can be introduced. ProOpter has a modular design and can be used as an add-on to existing production IT systems since it relies on established industrial communication standards. The use of the platform is validated on the well-known Tennessee Eastman benchmark simulation process and on two industrial case studies.     

Knowledge acquisition for decision support systems on an electronic assembly line

Increasing global competition has made many manufacturing companies recognize that competitive manufacturing in terms of low cost and high quality is crucial for success. Real-time process control and production optimization are, however, extremely challenging areas because manufacturing processes are getting ever more complex and involve many different parameters. This is a major problem when building decision support systems especially in electronics manufacturing. Although problem-solving is a knowledge intensive activity undertaken by people on the production floor, it is quite common to have large databases and run blindly feature extraction and data mining methods. Performance of these methods could, however, be drastically increased when combined with knowledge or expertise of the process.This paper describes how defect-related knowledge on an electronic assembly line can be integrated in the decision making process at an operational and organizational level. It focuses in particular on the efficient acquisition of shallow knowledge concerning everyday human interventions on the production lines, as well as on the factory-wide sharing of the resulting information for an improved defect management. Software with dedicated interfaces has been developed using a knowledge representation that supports portability and flexibility of the system. Semi-automatic knowledge acquisition from the production floor and generation of comprehensive reports for the quality department resulted in an improvement of the usability, usage, and usefulness of the decision support system.     

VirMIC—一个基于Internet的IC虚拟制造环境

该文展示了一个Internet环境下的集成电路虚拟制造环境VirMIC,着重于系统的三个核心模块,即电路性能仿真与成品率优化模块、工艺线仿真与调度模块和产品决策模块,电路性能仿真与成品率优化模块,建立了一个基于OO-DCE的技术CAD环境,以这个环境为依托,通过协调效益和成品率进行了工艺流程的可制造性优化设计;工艺线仿真与调度模块,以一定的工艺流程和制造系统配置为基础,建立制造系统Petri网模型,从而进行系统性能仿真和生产调度,对制造系统的整体性能进行优化;产品决策模块以前两个模块为基础,对如何选择合作伙伴,如何在合作伙伴之间分配用户提交的制造负荷,为构成“虚拟企业”提供指导性信息,以上三个模块构成了Vir-MIC系统的功能核心。     

设备状态检修管理系统研究

状态检修可以有效提高设备的可靠性和降低成本,目前正在我国的机电行业中大力推广应用。设计一个完整的设备状态检修管理系统,详细论述该系统的体系结构、功能模块以及数据库设计。目前已经应用该系统成功开发多个模块,取得良好的效果。     

Digital twin-driven rapid reconfiguration of the automated manufacturing system via an open architecture model

Increasing individualization demands in products call for high flexibility in the manufacturing systems to adapt changes. This paper proposes a novel digital twin-driven approach for rapid reconfiguration of automated manufacturing systems. The digital twin comprises two parts, the semi-physical simulation that maps data of the system and provides input data to the second part, which is optimization. The results of the optimization part are fed back to the semi-physical simulation for verification. Open-architecture machine tool (OAMT) is defined and developed as a new class of machine tools comprising a fixed standard platform and various individualized modules that can be added and rapidly swapped. Engineers can flexibly reconfigure the manufacturing system for catering to process planning by integrating personalized modules into its OAMTs. Key enabling techniques, including how to twin cyber and physical system and how to quickly bi-level program the production capacity and functionality of manufacturing systems to adapt rapid changes of products, are detailed. A physical implementation is conducted to verify the effectiveness of the proposed approach to achieving improved system performance while minimizing the overheads of the reconfiguration process by automating and rapidly optimizing it.     

设备状态检修管理系统研究

状态检修可以有效提高设备的可靠性和降低成本．目前正在我国的机电行业中大力推广应用。设计一个完整的设备状态检修管理系统,详细论述该系统的体系结构、功能模块以及数据库设计。目前已经应用该系统成功开发多个模块,取得良好的效果。     

一种面向汽车系统可靠性优化的任务分配方法*

对电子控制单元进行任务分配是汽车电子软件设计阶段一项非常重要的工作;以最大化系统可靠性为目标进行任务最优分配是一个NP-难问题。提出了一种改进的粒子群优化算法用于对任务进行近似最优分配以尽量提高系统的可靠性;通过在基本粒子群优化算法中引入一个新的变异操作有效提高了算法的收敛速度和解的精度。实验仿真表明该算法具有良好的有效性和可行性。     

基于RFID的单件生产实验系统的监控系统设计

采用面向对象的模块化方式对基于RFID的单件生产实验系统的上位机监控系统进行了设计,目的是通过对于该上位机监控系统的设计,能够对于生产过程进行实时控制和监控。为此通过多线程技术的应用实现了各模块的并发异步运行与通讯。文中给出了上位机与PLC通信模块,共享内存区服务模块及其访问模块,上位机与机械手控制程序通信模块,生产过程调度模块以及监控结果显示模块等5个模块的具体实现方法。系统运行良好,能够完成对整个生产过程的实时监控,证明了采用多线程技术确实可以很好地解决对于生产过程的实时控制和监控。     

Preview control of web position in roll-to-roll printing using alignment patterns

In printed electronics systems, the roll-to-roll process is a next-generation process technology that may be applied to the production of various electronic products such as flexible electronic devices, solar cells, and display panels. The process allows for production at low unit cost and high speed. As a factor for improving the print quality, there are ink viscosity, printing speed, printing pressure, and alignment precision. Among these factors, alignment precision, a critical factor in the performance of an electronic circuit, is the accurate alignment of layers in a multi-layered structure. In our previous study, we suggested a measurement method for improving the alignment precision by using an optical pre-measuring device and an alignment pattern that is printed by roll-to-roll printing process. In the measuring system, when a web is transported in the web feed direction, the optical pre-measuring device measures the quantity of light reflected by the alignment pattern. A lateral position can be aligned accurately based on the measured signal. However, because the position is measured in advance in the web feed direction, it is not applicable to a real-time printing system, and when the lateral position is measured using the optical pre-measuring device, a lateral position error, that is generated by disturbances induced by tension acting on the web and the vibration of the motor, can be estimated. A motor driven linear translation stage for lateral direction is used to minimize the lateral position errors in roll-to-roll systems. In this paper, we propose a preview control system to reflect the measured lateral position error to the printing result at the appropriate time for improving the alignment precision in roll-to-roll printing. As a control method, using roll-to-roll model, the system of disturbance, lateral angle and lateral position can be expressed as a state-space equation. Based on this equation, a preview controller to find the optimal value of state and control error is designed in a similar method to the conventional preview control method used for the active suspension system of a vehicle. Then, the alignment results are verified using another optical measuring device of a web transport system.

     

竖炉焙烧过程运行优化控制系统的开发及实验研究

为解决具有综合复杂动态特性的竖炉焙烧(shaft furnace roasting,SFR)过程运行优化控制问题,基于研制的流程工业一体化运行控制平台,开发了具有可伸缩、可扩展、可复用以及模块化、组态化特点的SFR过程运行优化控制(operational optimization control,OOC)系统.该系统支持MATLAB、动态链接库等多种算法实现方式,并采用非编译融合算法方式实现算法与系统功能模块的解耦.基于开发的OOC系统,建立了具有运行控制层、过程控制层以及虚拟对象层的半实物仿真实验平台,开展了相应的仿真实验研究.结果表明OOC系统在正常工况和局部故障工况下均能取得满意的控制性能.     

Digital twin-driven intelligent production line for automotive MEMS pressure sensors

The equipment and technological processes used in manufacturing electronic products are gradually being automated and networked. Currently, digital twin technology continues to evolve and mature. The electronics manufacturing industry is undergoing an intelligent and digital transformation. Micro-electro-mechanical system (MEMS) sensors have been widely used in the automotive field due to their small size, low cost, and high reliability. In this study, a new intelligent production line for automotive MEMS pressure sensors driven by digital twin is individually designed. The intelligent production line system consists of physical production lines, digital production lines, twin data, and data service systems. The technology of multi-source heterogeneous data acquisition is used to process and analyze data collected in real time in a physical production line. Based on the technology of parallel control, the physical and digital production lines are synchronized. To obtain optimal process parameters, a process database is established through the analysis of the key processes of the production line. Three types of automotive MEMS pressure sensors are successfully manufactured in the constructed digital twin-driven intelligent production line. The intelligent production line can realize 24-h unattended operation. The product yield is above 98 %, and the takt time is less than 16 s.     

A position measurement system for precision alignment of roll-to-roll printing and sensitivity analysis of thermal deformation

Roll-to-roll processing in the field of printed electronics is the process of creating electronic circuits or devices on a roll of flexible plastic or metal foil, and it can be used in the manufacture of many products, such as RFID tags, solar cells, and flexible display panels, at a much lower cost than that in the semiconductor lithography process. This process is also more efficient in producing electronic devices in a large volume than semiconductor lithography. As with lithography, roll-to-roll processing also needs to achieve accurate layer-to-layer alignment in fabricating multi-layered circuits or devices. This alignment precision, in fact, is a critical factor in determining the integration and performance of printed electronics. In other words, it is essential to achieve highly precise alignment in roll-to-roll printing for the full commercialization of printed electronics. To that end, this study proposes an alignment pattern that is directly printed on a web as a solution that can enhance the alignment precision in roll-to-roll printing. Based on this, the study also proposes a web position measurement system using optical measurement instruments and verifies its applicability and reliability. Considering the fact that tension on the web and heat generated in the process of curing may deform the web, we conducted experiments and simulations to analyze the measurement sensitivity when the web is actually deformed and we present the results of the study.     

Optimizing green production strategies: An integrated approach

Selection of green production strategy is a critical but difficult task due to the fact that it affects not only green benefits, but also production economy. The problem is essentially multi-objective and involves dynamic and uncertain conditions. This study focused on an integrated approach to improve the analysis and facilitate decision-making process. Discrete-event simulation model was developed to capture production flow and decision logic under real world conditions. A multi-objective genetic algorithm (MOGA), combined with improving heuristics, was developed to search the best solutions (Pareto optimums). The two modules are integrated to work in evolutionary cycles to achieve the optimization. Experiments were designed and carried out via a prototype system developed to verify and validate proposed concepts, including sensitivity analysis of related model parameters.     

氧化铝生产过程制造执行系统的研究

制造执行系统(MES)是连接上层企业资源计划(ERP)与底层过程控制系统(PCS)的桥梁,是基于ERP,MES,PCS三层结构的流程工业综合自动化系统的关键。针对氧化铝生产过程的特点,分析和探讨了氧化铝生产过程MES体系结构和功能,提出了氧化铝生产过程MES的功能模块设计。实践结果表明:氧化铝MES的实施实现了氧化铝生产过程,下层过程控制的实时信息和上层企业资源计划的信息融合与贯通,实现了氧化铝生产过程的优化控制、优化运行和优化管理,提高了企业的综合竞争力。     

铝粉氮气雾化和分级生产过程集成优化控制系统

在分析铝粉氮气雾化分级过程的特点和优化控制要求的基础上，设计了基于工控机和PLC以及现场I/O模块的分布式控制系统，实现了雾化和分级过程的集成控制.利用神经网络和遗传算法对铝粉氮气雾化过程进行建模和实施优化控制，提高了铝粉的雾化效果和细粉率，保证了生产的安全稳定运行.     

基于Java平台MVC模式的流程企业分析检测数据管理系统

该文针对流程企业普遍存在的分析检测数据传递滞后、准确性不够,严重影响生产效率和管理水平的现状,设计了一种基于Java平台和B/S(浏览器/服务器)模型的分析检测数据管理系统,满足分布式环境和跨平台的数据处理和传输应用要求。考虑到系统的易维护性和易扩展性,采用了先进的MVC(Model-View-Controller)模式,同时采用高性能的图形、报表处理模块及多种优化策略提高数据处理速度。该系统具有优越的系统性能:速度快,在300人同时浏览的负载情况下,页面的响应时间不超过200ms,长时间跨度的查询及报表生成不超过10s;准确性高,使用专业公式计算模块,精确到用户指定精度;使用灵活,用户可以自定义各种系统参数、报表及图表外观等;安全,通过数据库级和系统级两级安全措施保证系统数据完整安全,同时系统也具有友好的人机界面、良好的可维护性和可扩展性,较好解决了实际生产中信息传递不畅的突出问题,一定程度上提高了企业的生产效率和管理水平。     

蒸气压估算系统软件的建立

饱和蒸气压是重要的热力学性质之一，对于化学过程设计、仿真、优化与控制是必不可少的基础数据。本文建立的VPPS软件是用改进Riedel方程方法估算物质蒸气压的系统软件。该软件采用结构化设计。由单纯形优化算法、改进Riedel方程模块、新物质蒸气压预溅模块、统计比较模块4个主要模块以及基础数据库等组成。VPPS软件采用Microsoft Visual C 6．0编写，除界面部分外，将4个主要模块设计为一个文件，软件中所有用到的数据均保存为文本文件格式，该软件具有通用性强、易于使用、精确方便、可进一步开发等特点。     

基于三方通信构架电子政务安全系统的研究

作为政府机关事务管理的重要平台,一个安全、可靠的电子政务信息系统是实现政府信息化的必要保障。针对当前电子政务中存在的诸多安全问题,运用三方通信框架,提出了从制度上和技术上加强政府机关信息系统安全的相应措施及实现方案,较为详细地分析了三方通信的系统结构和流程,及实现强制权限访问控制的关键技术,构建了一种新型的电子政务应用平台。从而,使电子政务系统更安全、可行,显示出了良好的发展前景。     

Real-world production scheduling for the food industry: An integrated approach

The present paper offers an integrated approach to real-world production scheduling for the food processing industries. A manufacturing execution system is very appropriate to monitor and control the activities on the shop floor. Therefore, a specialized scheduler, which is the focus of this paper, has been developed to run at the core of such a system. The scheduler builds on the very general Resource Constrained Project Scheduling Problem with Generalized Precedence Relations. Each local decision step (e.g. choosing a route in the plant layout) is modeled as a separate module interconnected in a feedback loop. The quality of the generated schedules will guide the overall search process to continuously improve the decisions at an intermediate level by using local search strategies. Besides optimization methods, data mining techniques are applied to historical data in order to feed the scheduling process with realistic background knowledge on key performance indicators, such as processing times, setup times, breakdowns, etc. The approach leads to substantial speed and quality improvements of the scheduling process compared to the manual practice common in production companies. Moreover, our modular approach allows for further extending or improving modules separately, without interfering with other modules.     

基于三方通信构架电子政务安全系统的研究

作为政府机关事务管理的重要平台，一个安全、可靠的电子政务信息系统是实现政府信息化的必要保障。针对当前电子政务中存在的诸多安全问题，运用三方通信框架，提出了从制度上和技术上加强政府机关信息系统安全的相应措施及实现方案，较为详细地分析了三方通信的系统结构和流程，及实现强制权限访问控制的关键技术，构建了一种新型的电子政务应用平台。从而，使电子政务系统更安全、可行，显示出了良好的发展前景。