A hybrid PC/PLC architecture for manufacturing-system control—theory and implementation

This paper presents a novel and generic PC/PLC-based software/hardware architecture for the control of flexible manufacturing workcells. The proposed implementation methodology is based on the utilization of any one of the available formal discrete-event-system control theories in conjunction with state-of-the-art industrial programmable-logic controllers (PLCs). The methodology has been illustrated to be a viable technique through its actual implementation in our laboratory using a robotic-workcell testbed. The specific control theory used is a combination of Extended Moore Automata and Ramadge-Wonham Automata that has been developed by our research group. The modular control software architecture has been developed for MS-Windows environments (running on one PC interfaced to the PLCs) and allows the use of different formal control theories as well as different commercial PLC hardware. The effective graphical user interface provides a transparent programming environment, where users are not expected to have a full knowledge of the formal control theory used.     

An optimum design selection approach for product customization development

Consumer preferences and information on product choice behavior can be of significant value in the development processes of innovative products. In this paper, product customization evaluation and selection model is introduced to support imprecision inherent of qualitative inputs from customers and designers in the decision making process. Focusing on customer utility generation, an optimum design selection approach based on fuzzy set decision-making is proposed, where design attributes priority is identified from customer preferences using an analytical hierarchy process. A multi-attribute analysis diagram is developed to visualize the preference of each attribute from the expert’s group decision. Conjoint analysis is used in the product customization to focus on customer utility generation in terms of multiple criteria. The use of the decision-making method is illustrated with a case example that highlights the utility of the proposed method.     

Moore Automata for the Supervisory Control of Robotic Manufacturing Workcells

The potential of flexible-manufacturing workcells (FMCs) to produce a family of parts in many possible orders of operations and choices of different machines is advantageous. Despite intensive research on the theoretical control of discrete-event systems (DESs), however, current techniques can still only be used for the supervisory control of simple cells. In this paper, a novel modeling and control synthesis technique is presented for FMCs that allow part-routing flexibility. Our proposed methodology combines Extended Moore Automata (EMA) and Controlled-Automata theories to synthesize supervisors for such FMCs.     

Understanding how children understand robots: Perceived animism in child–robot interaction

Centuries ago, the existence of life was explained by the presence of a soul (Tylor, 1871). Known as animism, this term was re-defined in the 1970s by Piaget as young children's beliefs that inanimate objects are capable of actions and have life-like qualities. With the development of robots in the 21st century, researchers have begun examining whether animism is apparent in children's impressions of robots. The purpose of this study was to use a model of knowledge structures, or schemata, to examine whether children attribute human qualities of cognition, affect, and behavior to a robot. An experiment was set up at a science center located in a major Western Canadian city, and visitors to the center were invited to participate. A total of 198 children ages 5–16 years (M=8.18 years) with an approximate even number of boys and girls were included. Children completed a semi-structured interview after observing a robot, a small 5 degree of freedom robot arm, perform a block stacking task. Answers to the nine questions about the robot were scored according to whether they referenced humanistic qualities. Results from frequency and content analyses suggest that a significant proportion of children ascribe cognitive, behavioral, and especially affective, characteristics to robots.     

Robust adaptive control of a quadrotor helicopter

This work presents a direct approximate-adaptive control, using CMAC nonlinear approximators, for an experimental prototype quadrotor helicopter. The method updates adaptive parameters, the CMAC weights, as to achieve both adaptation to unknown payloads and robustness to disturbances. Previously proposed weight-update methods, such as e-modification, provide robustness by simply limiting weight growth. In order to let the weights grow large enough to compensate unknown payloads, the proposed method relies on a set of alternate weights to guide the training. The alternate weights produce nearly the same output, but with values clustered closer to the average weight so that the output remains relatively smooth. This paper describes the design of a prototype helicopter suitable for testing the control method. In the experiment the new method stops weight drift during a shake test and adapts on-line to a significant added payload, whereas e-modification cannot do both.     

Contingencies-based reconfiguration of distributed factory automation

In this paper, we describe our experience using a Java-based platform to implement an emerging real-time distributed control model (IEC 61499). We provide a simple example of a control application that is distributed across two devices (Dallas Semiconductor TINI boards) and also investigate how this distributed implementation can be exploited to enhance the system's fault tolerance using a contingencies-based approach to reconfiguration.     

Supervisory Control of Functionally-Expandable Manufacturing Systems

Supervisory controllers have traditionally coordinated the various resources of manufacturing systems, such as flexible manufacturing workcells, for the production of a priori set families of part types. This paper expands on this capability by allowing the control of the production of new part types side by side with previously defined and planned for nominal part types. The proposed basic workcell supervisory-control approach advocates the use of a pair of non-communicating independent supervisors, synthesized individually but working in concert, to achieve the production of existing and new part types: nominal and complementary supervisors, respectively. The nominal supervisor is responsible for controlling the behavior of the nominal system, producing the set of a priori planned-for part types, whereas the complementary supervisor controls the flow of the a priori unplanned-for new part types.     

Supervisory control of multiworkcell manufacturing systems withshared resources

Flexible-manufacturing systems (FMSs) may comprise a number of workcells where production resources are shared among the workcells for a variety of practical reasons. Although the utilization of independent workcells with sharing resources improves the flexibility of FMSs, avoiding deadlocks is essential for their successful implementation. This paper introduces a novel methodology for the synthesis of a set of conflict- and deadlock-free supervisors to individually control every workcell within a FMS inter-related by common (shared) resources. The proposed methodology is based on Extended Moore Automata (EMA) and Controlled-Automata theories. A new algorithmic procedure to analyze the concurrent operation of supervisors is also introduced in order to check for the existence or absence of deadlock states.     

Customer-driven product design and evaluation method for collaborative design environments

Product concept generation and evaluation in a product development environment has been identified as the two major activities needed for obtaining an optimal design scheme. Product conceptual design is of critical importance in design through customer involvement for the systematic and simultaneous consideration on the impact of design decisions on manufacturing and assembly leads to repeated and excessive changes in design and processes. This paper introduces a novel knowledge support approach for the organization and ranking of design feature knowledge towards an integrated product model that incorporates a feature-based representation scheme targeted to evaluate the impact of design on subsequent activities in the conceptual design phase, taking into account the presence of design information and user preferences. An uncertain linguistic multi-attribute decision-making evaluation model is proposed and discussed for obtaining an optimal design scheme during the evaluation and selection of product design alternatives in conceptual design. The focus of this paper is on the development of a knowledge-intensive support design scheme and a comprehensive systematic fuzzy evaluation methodology for product conceptual design generation, evaluation, and selection. A case study and the corresponding scenario of knowledge support for design alternatives generation, evaluation and selection are provided for illustration.     

Integral Backstepping Control of an Unconventional Dual-Fan Unmanned Aerial Vehicle

In this paper, a dynamic model of vertical take-off and landing (VTOL) aerial vehicles, having lateral and longitudinal rotor tilting mechanism, is first developed using a Newton–Euler formulation. Then an integral backstepping (IB) control technique is proposed to improve the pitch, yaw, and roll stability of the vehicle. Such control mechanisms enables the UAV to perform complex tasks that no other Unmanned Aerial Vehicles (UAVs) can execute such as hover pitched. This control tactic allows the vehicle under investigation, eVader, to use the full potential of its flying characteristics enabled by the novel dual-axis oblique active tilting (OAT) mechanism, which enables it to maneuver inside obstructed environments. The potential of the eVader as a small UAV and its model are verified and then used to for autonomous take-off and landing as well as stabilizing the vehicle’s attitude. Finally, diverse simulation scenarios on attitude and position control, stabilization and autonomous take off and landing are presented.