This paper provides an overview of a collaborative research program in information fusion from databases, sensors and simulations. Information fusion entails the combination of data from multiple sources, to generate information that cannot be derived from the individual sources. This area is of strategic importance for industry and defense, as well as public administration areas such as health care, and needs to be pursued as an academic subject. A large number of industrial partners are supporting and participating in the development of the area. The paper describes the program’s general approach and main research areas, with a particular focus on the role of information fusion in systems development
In a modern manufacturing environment, data and information are a vital part of the manufacturing process and in particular for supporting the value adding activities. Modern manufacturing information systems allow fast distribution of, and access to, data and information. However, the technical improvements of manufacturing information systems do not always create the benefits that were expected from them. This paper discusses this problem in the context of manual assembly tasks. Attention, interpretation and decision-making are important drivers for how well the assembly tasks are performed - the acting. In other words, the acting is governed by how and when the attention of the assembly operator is caught, how easily the information can be interpreted, and to what extent the information is useful for decision making. The aim with the work is to find and present why data and information provided on the shop floor often fails to prevent quality problems; not seldom this data and information actually causes the problems. This paper focuses on one of the core issues related to assembly data and information, namely “active attention” and how this is triggered. If active information seeking behaviour is not present on the assembly shop floor, then the probability for a quality problem increases.
Simulation can support the design of an ergonomic workplace by enabling early assessment of ergonomic conditions in a virtual environment. An important feature is the possibility to study alternative solutions or the effect of improvements from an ergonomics perspective. To be able to conduct an efficient and reliable evaluation in a virtual environment, an objective analysis method is essential. Such an analysis method should be integrated in the simulation software, and support a company’s everyday ergonomics work process. In order to gain from existing ergonomics knowledge within accompany, the possibility to implement such wisdom in the current simulation software becomes important.
This paper presents an implementation work done with the purpose of integrating an established ergonomics work process into a virtual environment. It describes the benefits of an ergonomics work process where simulation and evaluation at early stages of a design process are key factors. The paper will also describe the integration process, i.e. the technical issues as well as the change in work methods.
Simulation can support the design of an ergonomic workplace by enabling early assessment of ergonomic conditions in a virtual environment. An important feature is the possibility to study alternative solutions or the effect of improvements from an ergonomics perspective. To be able to conduct an efficient and reliable evaluation in a virtual environment, an objective analysis method is essential. Such an analysis method should be integrated in the simulation software, and support a company's everyday ergonomics work process. In order to gain from existing ergonomics knowledge within a company, the possibility to implement such wisdom in the current simulation software becomes important. This paper presents an implementation work done with the purpose of integrating an established ergonomics work process into a virtual environment. It describes the benefits of an ergonomics work process where simulation and evaluation at early stages of a design process are key factors. The paper will also describe the integration process, i.e., the technical issues as well as the change in work methods.
A work method for product and production system development that includes virtual methods for ergonomics analysis is presented and argued.The proposed work method is described and illustrated with an example,which the authors believe shows how a virtual work method can contribute to a better workplace design, and thereby, if utilised, would have prevented some of the design flaws that existed in the actual final product design in the example. This paper will also present the outcome, gain, and setbacks that are connected to the use of virtual work analysis methods within a design process.
This paper presents an overview of important aspects of air bending of sheet metal parts. Air bending is potentially a very flexible process when it comes to processing small batch sizes with a high variety. However, to exploit these benefits requires that both the processing of individual bends and the overall processing of a part be executed adequately. Important aspects are the bending process itself, in particular modeling and the calculation of punch penetration and bend allowance, the determination of bending sequences and tolerance reasoning. Some problems related to springback in air bending may be solved by combining it with, for instance, laser forming, while problems related to bend sequencing or accuracy may be solved in the design stage
This paper presents a description of Modelling & Simulation as used in the Virtual Systems Research Centre and issues discussed in previous FAIM and other papers, such as phases in a simulation project, Verification, Validation & Accreditation, and the use of simulation as a tool to reduce uncertainty. The role of the human in various phases/activities in simulation projects is highlighted. Two models for Information Fusion, the JDL and JDL-U model, are discussed. Subsequently, the activities and phases in a Modelling & Simulation project are placed in the context of the JDL-U model. This comparison shows that there are very strong similarities between the six (0-5) levels in the JDL-U model and activities/phases in Modelling & Simulation projects. These similarities lead to the conclusion that the JDL-U model with its associated science base can serve as a novel reference model for Modelling & Simulation.
This paper presents an overview of important aspects of air bending of sheet metal parts. Air bending is potentially a very flexible process when it comes to processing small batch sizes with high variety. However, to exploit these benefits requires that both the processing of individual bends and the overall processing of a part be executed adequately. Important aspects are the bending process itself, in particular modeling and the calculation of punch penetration and bend allowance, the determination of bending sequences, and tolerance reasoning. Some problems related to spring back in the air bending may be solved by combining it with for instance laser forming. Some problems related to bend sequencing or accuracy may be solved in the design stage.
This keynote gives a general description of simulation and its associated system of interest. In the context of virtual manufacturing, three domains can be distinguished; product domain, process domain and resource domain. Examples of simulation in these there domains are given, as well as some examples of simulation across these domains. Typical steps/phases in a simulation project are described, as well as common pitfalls. In industrial simulation projects, usually a number of stakeholders are involved with different maturity/experience in the field of simulation. It is described how such industrial simulation projects can be supported by a handbook, developed in close collaboration with a group of companies. As one example of advanced applications, simulation-based remote monitoring and diagnostics is described. The other example of advanced applications given in the paper is that of simulation-based optimisation.
This paper discusses information fusion including its nature as well as some models for information fusion. Research on information fusion is dominated by defence applications and therefore, most models to a certain extent are defence specific; it is explained how these can be made more generic by adapting them. It is explained how the manufacturing sector can benefit from information fusion research; some analogies between issues in manufacturing and issues in military applications are given. A specific area in which the manufacturing sector can benefit from research on information fusion is the area of virtual manufacturing. Many issues related to decision support through modelling, simulation and synthetic environments are identical for manufacturing and defence applications. A particular area of interest for the future will be verification, validation and accreditation of modelling and simulation components for synthetic environments with various involved parties.
This paper describes the factors that play a role in credibility of simulation results. It focuses on virtual manufacturing and in particular resource simulation as an example. However, a simulation model can be used in a number of different ways. Verification and validation of models is amongst other factors important for credibility. In this area, much work has been carried out in defense research. There are also some striking similarities between virtual manufacturing and information fusion, in particular in the field of human competence development related to credibility of simulations.
This chapter gives a general description of simulation and its associated system of interest. In the context of virtual manufacturing, three domains can be distinguished; product domain, process domain and resource domain. Examples of simulation in these three domains are given, as well as some examples of simulation across these domains. Typical steps/phases in a simulation project are described, as well as common pitfalls. In industrial simulation projects, usually a number of stakeholders are involved with different maturity/experience in the field of simulation. It is described how such industrial simulation projects can be supported by a handbook, developed in close collaboration with a group of companies. As one example of advanced applications, simulation-based remote monitoring and diagnostics is described. The other example of advanced applications given in the paper is that of simulation-based optimisation. Many simulation tools and projects aim at providing decision support to a human decision maker. High level information fusion, a development originating from defence research, also aims at providing decisions support. A comparison between virtual manufacturing and information fusion reveals that a popular reference model for information fusion called JDL-model is very apt to serve as a reference model for virtual manufacturing.
This paper presents a description of Modelling and Simulation as used in the Virtual Systems Research Centre at the University of Skövde. It also gives a summarized account of issues discussed in previous work such as phases in a simulation project, Verification, Validation and Accreditation, and the use of simulation as a tool to reduce uncertainty. The role of the human in various phases/activities in simulation projects is highlighted. Examples of both traditional and advanced applications of Virtual Manufacturing are given. Examples of the latter are simulation-based monitoring and diagnostics, and simulation-based optimization. Two models for Information Fusion, the OODA loop and JDL-U model, are discussed, the latter being an extension of the JDL model that describes various levels of information fusion (JDL=“joint directors of laboratories”). Subsequently, the activities and phases in a Modelling and Simulation project are placed in the context of the JDL-U model. This comparison shows that there are very strong similarities between the six (0–5) levels in the JDL-U model and activities/phases in Modelling and Simulation projects. These similarities lead to the conclusion that the JDL-U model with its associated science base can serve as a novel reference model for Modelling and Simulation. In particular, the associated science base on the “user refinement” level could benefit the Virtual Manufacturing community.
Information fusion, the synergistic combination of information from multiple sources, is an established research area within the defense sector. In manufacturing however, it is less well-established, with the exception of sensor/data fusion for automatic decision making. The paper briefly discusses some military specific models and methods for information fusion; analogies with manufacturing as well as a more generalized terminology are presented. “Manufacturing” is an application scenario within a Swedish information fusion research program that studies information fusion from databases, sensors and simulations with (currently) a focus on support for human decision making. An area of particular interest is that of advanced applications of virtual manufacturing such as synthetic environments, a form of hardware in the loop simulation that can deliver services such as service and maintenance at remote locations. In this area, the manufacturing industry can benefit from ongoing work in the defense sector related to verification, validation and accreditation of simulation models.
This paper describes manufacturing (resource) simulation with a focus on discrete event simulation and computer-aided robotics. Some generic good practices, problems and pitfalls in the use of simulation are described. Various advanced applications of manufacturing simulation are described and elucidated on the hand of a system for simulation-based service and maintenance. The paper also describes briefly how simulation-based decision support and information fusion are related, and how this can result in synergistic research across these areas
Robust and informed decisions are important for the efficient and effective operation of installed production facilities. The paper discusses Information fusion (IF) including a generic model for IF, and situations for decision-making. The paper also discusses current and future use of manufacturing resource simulation for design/configuration, operational planning and scheduling, and service and maintenance of manufacturing systems. Many of these applications use IF in some way, as is explained in more detail for simulation based service and maintenance. An extension of the generic model for IF is presented which incorporates modeling and simulation, and active databases as used in a simulation based service and maintenance system at the authors’ laboratory
Previous research has highlighted the role of virtual engineering tools in the development of manufacturing machinery systems. Simulation models created for this purpose can potentially be used to provide support for other tasks, such as operational planning and service and maintenance. This requires that the simulation models can be fed with historic data as well as with snapshot data. Furthermore, the models must be able to communicate with other business software. The paper describes how simulation models can be used for operational production planning and for service and maintenance support. Benefits include a better possibility to verify production plans and the possibility to monitor and service manufacturing machinery from remote locations. Furthermore, the expanded and continuously updated models provide a good tool to study the effect of, for instance, planned new product introduction in existing manufacturing systems. The paper also presents directions for future research. One ambition is to add AI tools to the system so as to develop a semi-autonomous system for decision support
The paper describes a new engineering Master's program called MMII (manufacturing management and industrial informatics) that is co-located at universities in Sweden, Spain and the United Kingdom. One reason for developing the program was that the changing manufacturing landscape due to globalisation, increasing complexity of manufacturing systems itself and an increased need to integrate manufacturing systems with corporate information systems forces educators to find solutions that provide industry with engineers who have the right skills. Apart from “hard” skills related to the above-mentioned issues, industry increasingly also requires engineers to have well-developed “soft” skills such as an ability to work in an international environment and willingness to work abroad. A program given at only one location would not provide a truly European dimension and besides, it would draw heavily upon the teaching resources; hence the decision to seek international partners with complementing competences and resources; these were found at universities in Skövde, Valencia and Loughborough. In Loughborough, students read capita selecta from CAE (computer aided engineering) during one semester. In Valencia, they spend a project-based semester on international industrial management. In Skövde, they read virtual manufacturing during one semester and carry out their degree project during the final semester.
The paper describes manufacturing simulation with a focus on discrete event simulation and computer aided robotics. Some generic good practices, problems, and pitfalls in the use of simulation are described. Some advanced applications of manufacturing simulation are described and elucidated on the hand of a system for simulation-based service & maintenance. Simulation-based decision support and information fusion are closely related, and plans for novel synergistic research in these area are presented
Electricity prices have gone up significantly during the last decade, and in some countries, the electricity price is very volatile. There exist a number of policies and regulations to control the electricity market and to stimulate energy efficiency, but these are often not very transparent. Furthermore, indicators for energy efficiency can be misleading or difficult to measure. Although there are a number of approaches to modelling and simulation of energy consumption and energy optimisation, these approaches have some drawbacks such as prohibitive computing times, difficulties to address dynamic situations, and the lack of a holistic view on the manufacturing system. Other problems include the limited availability of data at the appropriate level of aggregation; sometimes the level is too low, in other cases too high. However, recently promising attempts have been made to use Discrete Event Simulation for energy modelling and production planning. It is believed that this, in combination with other ICT tools such as multi-objective optimisation, offers a promising way forward beyond current state of the art.
Information Fusion encompasses "the theory, techniques and tools conceived for exploiting the synergy in the information acquired from multiple sources" [http://www.inforfusion.org/mission.htm]. The main issue is to improve the quality of decisions utilizing several information sources (databases, sensors, simulations). Research on information fusion has focused on applications like robotics and command and control systems, but the need of information synergy concerns more and more fields. Natural language serves as important information source in all areas of human activity, but the integration of language into fusion systems is far from satisfactory. The paper discusses employing language technology in bioinformatics, and in industrial processes.
Manufacturing organisations are continuously forced to improve the way of working to maintain their competitiveness on the global market. To optimize a production facility requires not only an optimal design of the whole line but also its internal operations sequencing and scheduling during the operational phase. The use of Virtual Manufacturing tools such as Discrete Event Simulation and Computer Aided Robotics has been proven to be highly effective both for production system design and for operational analysis and improvement. This paper proposes a new optimisation method, named SIMBOSeer, which synergistically combines the areas of optimisation, flexibility and virtual manufacturing that integrates robot simulation with simulation-based optimisation. Evaluation of SIMBOSeer, as applied to an existing manufacturing cell at a powertrain manufacturing company in Sweden, has shown that it can be used as an iterative process of analysis and optimisation. The results, when using realistic what-if scenarios, clearly point out that SIMBOSeer can facilitate the optimisation of operation sequences and decrease the total cycle time of the manufacturing cell. This is due to the fact that many non-value adding functions, such as unnecessary tool changes, which have a great negative impact on the effectiveness of the flexible manufacturing cell, can be avoided. Whilst the use of SIMBOSeer has obvious advantages under normal operating conditions of the cell, its use become even more beneficial when disturbance like tool failures occur or when product variants are introduced to the cell.
Computer aided visualization and simulation enables early assessment of important design parameters of future products and production systems. Typically, humans affect the system performance, and in order to achieve the expected system efficiency ergonomics needs to be considered in the design process in addition to the more technical or logistical matters. Hence, there is a call for ergonomics to be a natural part of the product and production system design process, also at virtual stages. This paper portrays and discusses two cases where company-specific ergonomics guidelines were implemented into digital human modeling systems for performing static work analyses. Albeit useful, the approach of evaluating static postures gives a reduced picture of the actual situation since the work usually involves a series of movements and tasks. A recently commenced research project aims to enhance knowledge on how to estimate accumulated ergonomic load over time. This knowledge is eventually to be implemented in DHM tools to support objective ergonomics analysis of complete work sequences in virtual environments.
Ergonomic evaluation typically comes late in the automotive design process, often not performed until physical mock-ups are produced. This may lead to expensive and cumbersome iterations, or to reductions of the final product quality due to low priority of meeting set ergonomic requirements. Computer aided design (CAD) is intensively used for design in the automotive industry. Performance and usability of computers and software are improving at a rapid pace, which enables CAD to be employed even more intensively. This encourages a digital design process where expensive, inflexible and time consuming physical mock-ups are only built at the end of the design process. This incorporates the risk that ergonomic evaluation will be put back even further. A way to address this problem is to enable ergonomics to be evaluated in the digital design process - in a virtual product. However, in many cases, evaluation made in a physical prototype is unbeatable in establishing ergonomic conditions. This paper discusses possible advantages of moving ergonomic evaluation earlier in the automotive design process by implementing planned overlapping strategies. It also shows initial results from a project at a car company, which aims at improving ergonomics integration in the automotive design process, e.g. by looking at task overlapping. These strategies are believed to be applicable both for evaluations made in a virtual environment and evaluations performed in the real world.
In this paper we present a visual odometry system for agricultural field robots that is not sensitive to uneven terrain. A stereo camera system is mounted perpendicular to the ground and height and traveled distance are calculated using normalized cross correlation. A method for evaluating the system is developed, where flower boxes containing representative surfaces are placed in a metal-working lathe. The cameras are mounted on the carriage which can be positioned manually with 0.1 mm accuracy. Images are captured every 10 mm over 700 mm. The tests are performed on eight different surfaces representing real world situations. The resulting error is less than 0.6% of traveled distance on surfaces where the maximum height variation is measured to 96 mm. The variance is measured for eight test runs, total 5.6 m, to 0.040 mm. This accuracy is sufficient for crop-scale agricultural operations.
The paper describes the design and development of a novel cost effective simulator for training of situation awareness, strategy and co-operation. By mixing real and virtual realities in combination with wireless and body-mounted hardware, the result is an augmented environment that allows for high physical mobility against a relatively low cost.
This paper proposes a novel low-cost robotic telepresence approach to situation awareness, initially aimed for hazardous environments. The robot supports omnidirectional movement, wide field of vision, haptic feedback and binaural sound. It is controlled through an augmented virtuality environment with an intuitive position displacement scheme that supports physical mobility. The operator thereby can conduct work away from danger whilst retaining situation awareness of the real environment.
Information management in 21st century industry has many aspects that have to be fully understood and covered in an information plan. With the emergence of CAD, problems with version management became more profound. Product data management (PDM) systems offered a partial solution, but these systems do not cover complete product life cycle support across complete supply/demand chain networks and seldom address manufacturing resource and process modeling in an adequate manner. This paper discusses some trends and tools in manufacturing information management and product life cycle support, with a focus on reuse of existing production resource information throughout the product process resource domain
In the era of globalization, one of the key factors for manufacturing machine builders/suppliers to remain competitive is their capability to provide cost-effective and comprehensive machine service and maintenance for their clients at anytime, anywhere. Previous research has highlighted the role of virtual engineering tools in the design and development life cycle of manufacturing machinery systems. Virtual engineering models created during the development phase can potentially be used to provide valuable functions for many other tasks during the operational phase, including service and maintenance support. This paper introduces an innovative Internet-enabled three-dimensional-based virtual engineering framework that can be used for such purposes. Specifically, it addresses a system architecture that is designed to facilitate the tight integration between virtual engineering tools and a set of Internet-based reconfigurable modular maintenance supporting tools. This system architecture has been verified by implementations using different toolsets atop of various Internet technologies (e.g. XML Web services and LabView's Datasocket). Implementation details and successful industrial-based test cases are also provided in this paper.
Virtual manufacturing, or manufacturing simulation, can be divided into three domains: product domain, process domain, and resource domain. This paper focuses on the use of virtual manufacturing for press line monitoring and diagnostics. It contains an introduction to virtual manufacturing, divided into a general part on modelling and simulation, verification, validation and acceptance, and the division into the three domains, as well as a specific part on the use of simulation in these domains for sheet metal products, processes and processing equipment. The main software tools discussed in this paper are discrete event simulation and computer-aided robotics; the designed and implemented machine service support system is an example of advanced use of three-dimensional (3-D) graphical simulation in the resource domain. This system offers remote on-line monitoring and diagnostics functions as well as media player-type functions such as replay that allow a service and maintenance expert to analyse disturbances that occur at remote locations. A key feature of the system is 3-D graphical simulation with I/O synchronisation. This type of system is particularly useful for system integrators and machine builders that install press lines and press cells world-wide and need to guarantee a high level of availability of the installed machinery.