Machining Cell Controller With Resource Arbitration for Fast Changeovers
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Solution Overview
Problem
Current machining cell controllers require expert knowledge to create and modify PLC programs, leading to high operating costs and time-consuming production process changes, especially in high-mix low-volume production scenarios where frequent changes are necessary.
Innovation Solution
A cell controller that allows operators to create and edit production programs without expertise in PLC languages, using production management units, sequence execution units, resource arbitration units, and a composite table storage unit to manage work resource allocation and process execution, thereby reducing the need for external specialists and streamlining production changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a PLC program is used to control the machining cell, then the production process can be automated, but the operating costs increase and production process changes take time due to requirement of expert knowledge
Solution Approach 1:
The patent creates a simplified copy or model of the PLC control system that operates independently from the original complex PLC program. This model allows operators to view and modify production processes without needing expert knowledge of PLC programming, while still controlling the actual machining cell through the resource arbitration unit.
Solution Approach 2:
The patent introduces an intermediary control layer between the operator and the PLC system. This intermediary consists of the simplified control interface and resource arbitration unit that translates operator actions into PLC commands, eliminating the need for operators to directly program or modify complex PLC logic.
2Extent of automation
If a PLC program is used to control the machining cell, then the production process can be controlled, but the time to change production process increases due to outsourcing requirement
Solution Approach 1:
The patent enables operators to independently modify production processes using the simplified control interface without requiring external system integrators. The resource arbitration unit automatically handles the complexity of coordinating multiple work resources, allowing operators to focus on high-level process changes rather than detailed programming.
Solution Approach 2:
The patent separates the control system into two distinct layers: a simplified operator interface for process modification and the underlying PLC system for execution. This segmentation allows operators to work with intuitive process definitions while the system automatically manages the complex coordination required for multi-resource production.
3Productivity
If multiple workpieces are produced in parallel, then productivity increases, but work resource contention occurs between workpieces
Solution Approach 1:
The resource arbitration unit dynamically adjusts work resource allocation based on real-time system state and predefined arbitration rules. When multiple workpieces compete for the same resource, the system automatically determines priority based on factors such as process stage, resource availability, and production schedules, ensuring fair and efficient resource distribution.
Solution Approach 2:
The patent implements a feedback mechanism where the resource arbitration unit continuously monitors work resource status and adjusts allocations accordingly. The system receives feedback from work resources about their availability and state, and uses this information to make real-time arbitration decisions that prevent conflicts and optimize parallel production.
Data Source
AI summary
Provided is a cell controller for controlling an operation of a machining cell including two or more machines and one or more robots as work resources, the cell controller being configured to control the operation of the machining cell based on a production program recorded with one or more processes to be executed at the time of producing only one article of a corresponding item in the machining cell among production programs prepared corresponding to one or more items produced in the machining cell.