An Operating System for Cyber-Physical Manufacturing (OSCM) to enable and grow Cyber-Physical Manufacturing Networks (CYMAN)

Toro Santamaria, Ricardo

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https://hdl.handle.net/2142/120095 Copy

Description

Title

An Operating System for Cyber-Physical Manufacturing (OSCM) to enable and grow Cyber-Physical Manufacturing Networks (CYMAN)

Author(s)

Toro Santamaria, Ricardo

Issue Date

2023-04-27

Director of Research (if dissertation) or Advisor (if thesis)

Ferreira , Placid M

Doctoral Committee Chair(s)

Ferreira , Placid M

Committee Member(s)

• Kapoor, Shiv G
• Nahrstedt, Klara
• Shao, Chenhui

Department of Study

Mechanical Sci & Engineering

Discipline

Mechanical Engineering

Degree Granting Institution

University of Illinois at Urbana-Champaign

Degree Name

Ph.D.

Degree Level

Dissertation

Keyword(s)

• Operating System for Cyber-Physical Manufacturing (OSCM)
• Cloud Manufacturing (CM)
• Industry 4.0
• Digital Manufacturing
• Pub-Sub
• Event-driven - Messaging Systems
• Information Systems
• Smart Manufacturing (SM)

Abstract

The evolution of factory technologies has enabled a significant level of manufacturing flexibility through the use of programmable automation such as CNC and PLCs, hardware innovations such as quick-change tooling, and operator assist technologies. However, the manufacturing information system remains the most inflexible aspect of a factory. These systems are typically customized for manufacturers by system integrators and are often composed of large monolithic systems built around an ERP/MRP framework or a collection of decision-support software tools that are poorly integrated, with a patchwork of communication channels connecting them. On the other hand, cloud-based information service platforms, such as those used in social networks and service brokers, have experienced multiple cycles of rapid evolution, resulting in a tremendous increase in their ability to handle increasingly large data scales and rates while maintaining their elasticity and flexibility. This swift advancement of cloud-based information services has sparked a new era in the manufacturing industry, as evident in the emergence of manufacturing cyber-physical system technologies, including the Industrial Internet of Things (IIoT) and Cloud Manufacturing (CM). These technologies are part of the broader context of the unfolding fourth industrial revolution, also known as Industry 4.0 or Digital Manufacturing. This revolution emphasizes the importance of connectivity, information, and machine-based intelligence to create a new paradigm for manufacturing that is highly flexible, scalable, responsive, and intelligent. The work proposed in this dissertation facilitates the digital transformation of manufacturing organizations by designing, implementing, and testing an infrastructure platform that can handle shopfloor information. This platform, called Operating System for Cyber-Physical Manufacturing (OSCM), combines cloud and edge elements to achieve three objectives: (1) enable connectivity and interaction between manufacturing jobs, machines, and manufacturing software applications; (2) capture the events and data that result from these interactions; and (3) process, distribute, store, and serve them to the desired end-points. The dissertation explores how modern cloud and web computing concepts and frameworks, such as containerization, microservices, event-based designs, and pub-sub messaging, can be utilized to develop a configurable, user-friendly, flexible, and scalable information environment for the manufacturing shopfloor. The first portion of the dissertation introduces the software architecture for OSCM that is envisioned to facilitate and track the interaction between a manufacturing job, physical resources, and the software services (or apps) around them. Then, the dissertation provides a comprehensive explanation of an event-based architecture for OSCM. This architecture allows for flexible distribution of resource or transaction-related events/data to various decision-making and manufacturing software tools through an event/message service. The following chapter examines the performance of the proposed event-driven service. To evaluate the system's capabilities and identify its limitations, multiple experiments are designed and conducted. Then, practical recommendations are made based on the findings of the experiments to assist in the deployment and implementation of OSCM. The subsequent Chapter outlines seven different applications and discusses their potential benefits. These applications include a research collaborative tool, an archival data storage system for supporting AI and machine learning analytic tools, three different monitoring applications with varying implementation complexities, a production line simulator tool, and an automated work-order execution system, which demonstrates the control capabilities of applications within the OSCM ecosystem. The dissertation concludes by providing a comprehensive summary of the proposed framework infrastructure's benefits and advantages in comparison to traditional manufacturing operations and information systems. Furthermore, it offers valuable insights into potential areas for future research based on the investigation presented in this dissertation.

Graduation Semester

2023-05

Type of Resource

Thesis

Copyright and License Information

Copyright 2023 Ricardo Toro Santamaria

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