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- Petri nets approach for designing the migration process towards industrial cyber-physical production systemsPublication . Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, PauloPresently, many industries are facing strong challenges related to the demand of customized and high-quality products. These pressures lead to internal company's conflicts where current production systems have a rigid structure, forcing the company into a organization stall when a fast product change is required. Therefore, the need to smoothly migrate traditional systems into more feature-rich and cost-effective systems, namely Cyber-Physical Production Systems (CPPS), became a highly discussed topic. PERFoRM project focuses the conceptual transformation of existing production systems towards plug\&produce ones to achieve flexible and reconfigurable manufacturing environments. In particular, the smooth migration process is considered crucial to effectively transpose existing production systems into truly CPPS. This paper describes the use of Petri nets to design the migration process under the PERFoRM perspective, taking advantage of its inherent capabilities to design, analyze, simulate and validate such complex processes.
- Migration from traditional towards cyber-physical production systemsPublication . Cala, Ambra; Luder, Arndt; Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, Paulo; Gepp, MichaelNowadays, many organizations intend to convert their existing production systems towards ones that are characterized by adaptability, openness, flexibility and modularity. This requires a redesign of existing information processing systems especially related to control, leading possibly to cyber-physical production systems (CPPS). However, the implementation of new control technologies will have a direct impact on the normal operational status of production while engineers will also face several challenges and obstacles in adopting intelligent automation systems. New step-wise migration strategies are required to holistically support industries in their journey towards CPPS taking into account technical, economic and social aspects. This paper discusses the migration state-of-the-art strategies, analyzing them and providing a first attempt to define a migration approach for innovative production systems.
- Development of ergonomic user interfaces for the human integration in cyber-physical systemsPublication . Cachada, Ana; Barbosa, José; Leitão, Paulo; Deusdado, Leonel; Costa, Jacinta Casimiro da; Teixeira, João Manuel; Teixeira, Carlos; Romero, Luís; Moreira, Pedro MiguelDigitalization is transforming the worldwide economy. In such digital transformation the human integration in CPS assumes a crucial importance, complemented with some key enabling technologies like IoT, cloud computing, big data and machine learning. In this context, user interfaces are used to collect data and to monitor and control the systems, being required to use design and ergonomics guidelines, as well as user expirience, for their deployment in industrial enviroments. This paper describes the use of friendly and ergonomic user interfaces to support the human integration at operational and strategic level, aligned with the Industry 4.0 context, for an industrial metal stamping unit.
- Maintenance 4.0: intelligent and predictive maintenance system architecturePublication . Cachada, Ana; Barbosa, José; Leitão, Paulo; Geraldes, Carla A.S.; Deusdado, Leonel; Costa, Jacinta Casimiro da; Teixeira, Carlos; Teixeira, João Manuel; Moreira, Antonio H.J.; Moreira, Pedro Miguel; Romero, LuísIn the current manufacturing world, the role of maintenance has been receiving increasingly more attention while companies understand that maintenance, when well performed, can be a strategic factor to achieve the corporate goals. The latest trends of maintenance leans towards the predictive approach, exemplified by the Prognosis and Health Management (PHM) and the Condition-based Maintenance (CBM) techniques. The implementation of such approaches demands a well structured architecture and can be boosted through the use of emergent ICT technologies, namely Internet of Things (IoT), cloud computing, advanced data analytics and augmented reality. Therefore, this paper describes the architecture of an intelligent and predictive maintenance system, aligned with Industry 4.0 principles, that considers advanced and online analysis of the collected data for the earlier detection of the occurrence of possible machine failures, and supports technicians during the maintenance interventions by providing a guided intelligent decision support.
- Migration strategy toward innovative, digitalized, and harmonized production systemsPublication . Cala, Ambra; Cachada, Ana; Pires, Flávia; Barbosa, José; Wermann, Jeffrey; Colombo, Armando W.Industry today is facing the fourth Industrial Revolution, also called Industry 4.0, pulled by the market demand of shorter delivery time and product life cycles, with increased product variety and smaller lot sizes, and pushed by innovative technologies, such as Cloud computing, big-data analysis, connected Cyber-Physical Systems (CPSs), Internet of Things, and related services, as well as autonomous robots and augmented reality. Industry 4.0 is an industrial paradigm that is proposing to transform the traditional factories into smart factories, which are more competitive, efficient, and productive. The goal is the rapid introduction of new tangible products and intangible products (services) into the market as soon as market and customer requirements change. In order to achieve this goal, the production process itself should be more agile and particularly correctly digitalized.
- Conceção e projeto de um centro de maquinagem CNC de 5 eixosPublication . Cachada, Ana; Queijo, Luis; Rocha, JoãoResumo Este trabalho consistiu em conceber e projetar um centro de maquinagem CNC com 5 eixos adequado à maquinagem de materiais macios, como por exemplo poliuretano. Este centro maquinagem deve apresentar uma volumetria de trabalho máxima de 0,5x0,5x0,5 m3. O desenvolvimento deste trabalho passou pela análise de diversas estruturas, passiveis de serem utilizadas como estrutura base de um centro de maquinagem com 5 eixos, cálculo dos esforços a que a estrutura está sujeita, cálculo das velocidades de trabalho e cálculo da massa máxima dos materiais a maquinar. Definidas as condições iniciais do modelo foi necessário selecionar os perfis a utilizar na estrutura da máquina-ferramenta e ainda todos os elementos integrantes dos sistemas de movimentação linear e rotativa, como fusos, motores, rolamentos, engrenagens, polias, entre outros. Além dos elementos standard selecionados foi essencial proceder à conceção de elementos de ligação e suporte criados especificamente para o equipamento, como apoios para os motores e fusos, cantoneiras, entre outros. Posteriormente, realizaram-se simulações estáticas para verificar se todos os componentes suportam os esforços que lhe são impostos e perceber quais as deformações sofridas por estes. Através da análise das deformações e dos deslocamentos mínimos conseguidos foi possível determinar qual a exatidão do equipamento. Por fim, com base em orçamentos e preços estimados foi efetuada uma estimativa de custo total do equipamento.
- Modelação matemática da camada de plasma em microcanaisPublication . Cachada, Ana; Pereira, Ana I.; Lima, Rui A.Este trabalho apresenta um estudo relativo à modelação matemática da camada de plasma observada nos escoamentos sanguíneos. Numa fase inicial a resolução do problema fez uso da otimização global não linear, mais propriamente, uso do Algoritmo Genético (AG), para encontrar a função que minimiza o erro quadrático entre a função testada e os dados numéricos obtidos nas camadas de plasma. Assim, foram testadas quatro funções que consistem na combinação de funções trigonométricas. Posteriormente, e para melhorar os resultados numéricos obtidos mais de quarenta funções foram testadas usando a ferramenta cftool. Com este estudo pretende-se encontrar um modelo matemático que se ajuste aos dados numéricos que caracterizam a camada de plasma. De todas as funções testadas as que apresentam os melhores resultados são baseadas em somas de três a oito termos de senos. Posteriormente, recorreu-se aos métodos Simulated Annealing, Pattern Search e Quasi-Newton de modo a averiguar se algum deles seria capaz de encontrar uma solução menor em comparação com os resultados obtidos pelo AG, a função testada foi a soma de oito termos de senos. Na fase final deste estudo foram testados dados referentes a três escoamentos com diferentes características. As três melhores funções do estudo anterior foram selecionadas e testadas através do AG. A análise global dos resultados permite afirmar que o modelo baseado na soma de senos é o que melhor caracteriza a camada de plasma.
- Petri nets methodology for the design and control of migration processes towards industry 4.0Publication . Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, Paulo; Cala, AmbraThe fourth industrial revolution, commonly known as Industry 4.0, germinated in Germany as an industrial program of the government to reinvigorate the manufacturing sector. Nowadays, this change in the industrial paradigm has reached a global scale and is proposing to transform the traditional factories into more competitive, efficient and productive industries. In order to accomplish this goal it is necessary to establish methodologies to migrate from the traditional systems to innovative systems, namely those applying the Cyber-Physical Production Systems (CPPS) concepts. This paper proposes a methodology based on the Petri nets formalism for the modelling, analysis, validation and simulation of the migration process during the design phase and the control and monitoring of such processes during the implementation phase.
- Intelligent and predictive maintenance in manufacturing systemsPublication . Cachada, Ana; Leitão, Paulo; Barbosa, JoséIn recent years manufacturing companies have been facing a major shift in the manufacturing requirements, for example the shift in demand for highly customized products resulting in a shorter product life cycle, rather than the traditional mass production of standardized products. As a consequence of the change, the enterprises are facing the need to adapt, forcing all sectors of the manufacturing activity to move accordingly. Maintenance is one of the major activities in manufacturing as it highly influences production productivity and quality, and has a direct impact on production cost and customer satisfaction. Nowadays, corrective and scheduled maintenance are widely implemented. However, the manufacturing world need to adapt to this new reality by implementing new, intelligent and innovative maintenance systems capable of predicting in advance possible failures. Lately, predictive maintenance systems and tools have been developed and continue to be studied and improved. However, companies do not have enough trust on these systems to fully rely on them. Considering all these aspects, the work developed on this thesis introduces a system architecture for an intelligent predictive maintenance system based on the Condition-Based Maintenance (CBM) to be used in the Catraport case study, focusing particularly on the development of the monitoring module of the system architecture. This module comprises a tool developed by using Node-RED that displays the collected data alongside with the warnings triggered by cross-checking the incoming data with implemented decision rules, through the use of graphics and text. Additionally, an Android mobile application was also developed to allow consulting remotely the operating state of the assets.
- Digital twin in industry 4.0: technologies, applications and challengesPublication . Pires, Flávia; Cachada, Ana; Barbosa, José; Moreira, António Paulo G. M.; Leitão, PauloThe digital transformation that is on-going world-wide, and triggered by the Industry 4.0 initiative, has brought to the surface new concepts and emergent technologies. One ofthese new concepts is the Digital Twin, which recently started gaining momentum, and is related to creating a virtual copy ofthe physical system, providing a connection between the real and virtual systems to collect and analyze and simulate data in thevirtual model to improve the performance of the real system. The benefits of using the digital twin approach is attracting significant attention and interest from research and industry communities in the last few years, and its importance will increase in the upcoming years. Having this in mind, this paper surveys and dis-cusses the digital twin concept in the context of the 4th industrial revolution, particularly focusing the concept and functionalities, the associated technologies, the industrial applications and theresearch challenges. The applicability of the digital concept isillustrated by the virtualisation of an UR3 collaborative robot which used the V-REP simulation environment and the Modbus communication protocol